Sustainable Plastics - March/April 2022 - 24

additive manufacturing
continued from page 22
can generate waste if filaments
being used are based on fossil
fuels. As the manufacturing industry
shifts, this is something
that needs to be addressed. The
filaments used in AM must be
eco-friendly and must be made
from materials that have proven
their sustainability value from
their production through their
integration into new products.
Luckily, more sustainable options
are entering the market.
The options of filaments marketing
their sustainable value
propositions are numerous and
varied. These include materials
made from recyclable plastics,
plastic print waste for filaments,
bio-degradable materials and
PLA, a cornstarch-based 3D
printing material. This is important
since 3D printing filaments
made from sustainable materials
can play a major role in climate
change mitigation.
Not all filaments are created
equal; the sustainability properties
vary greatly depending
on the raw material used. Some
filaments are made from plantbased
material, or landfill waste
like UBQ, while another popular
option is ABS, a common thermoplastic
polymer, which is a
material that can be recycled, reprocessed,
and reused. To date,
the most sustainable 3D printing
filaments used in AM have been
largely based on a glycol-modified
version of polyethylene terephthalate
(PETG). However, this
material has limited properties
and has confined use cases to dimensional
models and dummies.
Growing interest in this novel
production approach from both
investors and manufacturers alike
is propelling the move towards
sustainable AM, including developing
the raw materials required,
which can truly set AM apart as
the best option for production.
Finding truly sustainable
material options
To achieve the full sustainability
benefits of AM, however,
we must ensure that the 3D
filaments used are truly sustainable.
So, if the material is plantbased,
but requires significant
water to grow in the first place,
it may look sustainable, but its
negative environmental impact
24
March/April 2022
is simply felt elsewhere.
We must therefore quickly
identify raw material sources
that are infinite, cost-effective,
and shift production to circular
models. If we can create new
end-of-life solutions for waste
that is typically seen as unrecyclable,
we can close the loop
on the production cycle with
circular solutions. For example,
utilising waste from landfills that
can be converted to a climate
positive thermoplastic within 3D
printing filaments is a new option
for AM that enables sustainable
and eco-conscious manufacturing
practices. UBQ Materials
recently worked together with
Plastics App, an innovative R&D
polymers and plastics company,
to develop such a filament.
What's stopping
companies from
transitioning to AM?
So, why hasn't everyone and
everything transitioned to 3D
printing? Seemingly, it can be
cost effective, and with the right
material choices, AM can be a
much more sustainable way to
produce goods. While the answers
are nuanced depending
on who you ask, more often
than not, it boils down to cost.
While 3D printing a product
may be cost-effective, according
to a 2020 study in the
biomedical sector, the cost of
transitioning to AM can be extremely
financially taxing for
companies, especially smaller
producers. Materials, utility, and
technological maintenance can
be expensive, putting aside the
cost of implementing 3D printing
hardware, software, system
integration, and the cost of 3D
printers themselves.
The study also found that companies
from across manufacturing
sectors, which adopt the
technology without redesigning
their organisational structure and
processes, encountered difficulties.
This barrier to entry is often
enough of a sticking point to justify
moving slower.
What's more, creating components
without machining or tools
can lead to efficiency and design
faults with many prints sometimes
needed until a correct model is
created - more added costs. This
wastage can grow into a problem
The latest white paper sponsored by additive manufacturing
company Essentium entitled Trends in 3D Printing at Scale: A
Survey of 3D Printing in Production Manufacturing December
2021 reviewed the results of an online survey of 161 managers
and executives working at manufacturing companies with responsibility
for 3D printing at scale. The participants were asked
about a wide range of topics related to the present and future use
of industrial 3D printing and their opinions on outcomes.
According to this report, manufacturers still face obstacles
in the adoption of 3D printing at scale, with many manufacturing
companies still struggling to incorporate this technology
into their operations. To better understand why the adoption
of 3D printing for large-scale production continues to be difficult,
manufacturing managers and executives were asked to
identify their greatest obstacles. The top challenge cited is its
high cost (45%) followed by current 3D capabilities not meeting
application requirements (43%), the level of change to current
manufacturing processes is too extreme (36%), the lack of expertise
(26%), and unreliable materials (25%). One stakeholder
also wrote certification as an " other " challenge.
When asked explicitly if the materials for 3D printing could be
improved, 100% of manufacturing stakeholders want changes,
with resistant materials (44%) topping their lists. Other key improvements
include materials that speed time to market (37%),
open materials that can be used on any machine (36%), materials
designed specifically for industrial-scale production (34%),
advanced materials for handling processes (31%), and more.
for the environment and companies'
bottom lines.
Fortunately, innovators are
working to address this challenge
as well.
A trend that must
catch on
The benefits of AM can outweigh
the challenges when
it comes to carbon footprint
reduction. It's a trendy and
novel way for manufacturers
to produce goods, and it is
attracting innovative developments,
so we will certainly
see rapid evolution and progress
in this space to address
these challenges.
Beyond the initial capital
expenditure, 3D printing
goods is cost-effective, energy-efficient,
and cuts down
transportation needs, which
all contribute to minimizing
greenhouse gas emissions.
Moreover, 3D printing is less
reliant on finite raw materials
in the printing process.
By adopting truly sustainable
and cost-competitive raw
materials for 3D printing, manufacturers
may find a more
efficient way to approach additive
manufacturing, while
simultaneously minimizing
waste, and preventing significant
harmful emissions associated
with traditional manufacturing
practice.
Contributed by Gil Felus,
Chief Operating Officer, UBQ
Materials
Sustainable Plastics - March/April 2022

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