Carbon Footprint of Wire Arc Additively Manufactured Optimized Structural Steel Element

Abstract Metal Additive Manufacturing (AM), and particularly Wire Arc Additive Manufacturing (WAAM), opens new opportunities for steel structures by enabling efficient, reliable, and material‐saving solutions with reduced environmental impact. The AEC sector is starting to adopt WAAM for full‐scale structural elements, benefiting from its design freedom. However, tailored design approaches are needed to fully harness its potential and realize geometries unachievable with conventional methods. This study evaluates the environmental performance of a novel steel structural element featuring a Tubular Sandwich Section (TSS), fabricated using WAAM. The TSS, which defines the section of the structural element, consists of inner and outer cylinders connected by internal spokes, providing improved radial strength and better alignment with structural requirements. Its performance is compared to that of a conventional Circular Hollow Section (CHS), manufactured through cold forming with equivalent diameter and radial capacity. A cradle‐to‐gate analysis shows that WAAM enables a lighter and more sustainable alternative, highlighting its promise in reducing the carbon footprint of the construction sector.