Process impact assessment towards enhancing sustainability in three-dimensional sand printing

¹ University of Johannesburg, Department of Engineering Metallurgy, 2094 Johannesburg, South Africa
² Cape Peninsula University of Technology, Department of Mechanical and mechatronics Engineering, 7535 Cape Town, South Africa
³ University of Johannesburg, Department of Chemical Engineering Technology, 2094 Johannesburg, South Africa
⁴ University of Johannesburg, Department of Engineering Metallurgy, 2094 Johannesburg, South Africa

^* A. Motlhabane: accolademotlhabane@gmail.com

Abstract

Three-dimensional (3D) sand printing process using additive manufacturing offers design flexibility and faster production but generates significant waste. This study applies a process impact assessment or partial life cycle analysis (LCA), to evaluate its environmental impact, identifying inefficiencies and areas for improvement. The analysis focused on material usage, waste generation, and energy-related CO₂ emissions. For the defined functional unit of 15 furan-based silica sand cores (2.50 kg each), results showed 92.5% of coated sand remained unused after a build, and electricity use over a 6.83 h cycle resulted in 1.09 t CO₂ (Scope 2) emissions. The findings highlight opportunities for renewable energy adoption, material reclamation, and landfill reduction. Integrating circular economy principles could enhance sustainability in sand printing. This approach underscores the need to rethink waste management practices and optimize resource efficiency in additive manufacturing.