Additive Manufacturing as a Catalyst for Low-Carbon Production and the Renewable Energy Transition in Electric Vehicles

Additive manufacturing (AM), or 3D printing, is increasingly recognised as a disruptive production technology with the capacity to reduce greenhouse gas (GHG) emissions across manufacturing and transportation sectors. By enabling material efficiency, lightweighting, part consolidation, and decentralised, on-demand production, AM offers pathways to lower embodied energy, minimise waste, and shorten supply chains. This review critically evaluates AM’s role in decarbonisation, with a focus on clean transportation applications, including electric vehicles, fuel cells, and hydrogen storage systems. Case studies quantify energy savings, operational efficiency gains, and life-cycle GHG reductions compared to conventional manufacturing routes. The analysis also addresses technical and economic limitations—such as material availability, scalability, certification, and cost competitiveness—and explores synergies with circular economy principles, digital design optimisation, and artificial intelligence. Policy recommendations and industry–academia collaboration models are proposed to accelerate AM adoption, integrate renewable energy sources, and strengthen recycling infrastructure. By synthesising technical, economic, and policy perspectives, the study positions AM as a critical enabler of net-zero manufacturing and a catalyst for sustainable industrial transformation.