Simulation-Driven Build Strategies and Sustainability Analysis of CNC Machining and Laser Powder Bed Fusion for Aerospace Brackets

This study provides a detailed technical and sustainability comparison of the conventional CNC machining and additive manufacturing routes for an aerospace bearing bracket. The work integrates material selection, process parameterization, build simulation, and environmental–economic assessment within a single framework. For the CNC route, machining of Al 7175-T7351 is characterized through process sequencing, tooling requirements, and waste generation. For the Laser Powder Bed Fusion (LPBF) route, two build strategies, single-part distortion-minimized and multi-part volume-optimized, are developed using Siemens NX for orientation optimization and Atlas3D for thermal and recoater collision simulations. The mechanical properties of Al 7175-T7351 and Scalmalloy® are compared to justify material selection for aerospace applications. Both the experimental and simulation-derived process metrics are reported, including the build time, support mass, energy consumption, distortion tolerances, and buy-to-fly (B2F) ratio. CNC machining exhibited a B2F ratio of 1:7, with cradle-to-gate CO2 emissions of ~11,000 g and an energy consumption exceeding 100 kWh per component. In contrast, both LPBF strategies achieved a B2F ratio of 1:1.2, reducing CO2 emissions by over 90% and energy consumption by up to 63%. Build volume optimization further reduced the LPBF unit cost by over 50% relative to the CNC machining. Use-phase analysis in an aviation context indicated estimated lifetime fuel savings of 776,640 L and the avoidance of 2328 tons of CO2 emissions. The study demonstrates how simulation-guided build preparation enables informed sustainability-driven decision-making for manufacturing route selection in aerospace applications.