Definition of a life cycle engineering tool to support the ecodesign in additive manufacturing: application to FDM technology

Abstract This study introduces a comprehensive life cycle model and tool to support the ecodesign of 3D printed components. The model, developed for Fused Deposition Modeling (FDM) technology, integrates both product and process-related parameters and encompasses all life cycle stages: (i) raw material production, (ii) part manufacturing, (iii) use, including application context and maintenance, (iv) end-of-life, and (v) transport. The model enables the predictive evaluation of environmental and economic performance through life cycle assessment (LCA) and life cycle costing (LCC), respectively, and using engineering design parameters as input. The FDM life cycle tool aims to guide decision-making during the early design phases by integrating sustainability metrics alongside conventional design requirements. It constitutes the kernel of a broader approach (called eDAM—ecodesign for Additive Manufacturing), which incorporates life cycle models, extensive data inventories, and technology-specific ecodesign guidelines. However, the development and implementation of the framework fall beyond the scope of the present study. The FDM model’s applicability is demonstrated through a case study involving the production of a lightweight aerospace component (aircraft interior panel). The bio-inspired optimized 3D printed part exhibits notable reductions in greenhouse gas emissions and life cycle costs, confirming AM’s potential for sustainability improvements in dynamic applications, including aeronautical systems. This tool outperforms other commercial tools used for environmental and cost assessment in additive manufacturing, in terms of built-in functionalities, product life cycle phases, and database breadth. The research highlights the scalability of the eDAM approach and its capacity to support engineers in achieving a balance between technical, economic, and environmental performance. Future work will extend the model to additional AM and conventional manufacturing technologies, refine specific life cycle phases (e.g., use-phase and end-of-life scenarios), and evaluate the usability and implementation efficiency of the model within the broader ecodesign framework. Graphical abstract