Energy and material efficiency strategies enabled by metal additive manufacturing – A review for the aeronautic and aerospace sectors

Conventional manufacturing of aeronautic and aerospace parts requires substantial amount of resources (energy and materials) while generating high quantities of waste and carbon dioxide emissions. Metal additive manufacturing (MAM) has the potential to reduce resource consumption, which is particularly important for energy-intensive materials such as titanium. We undertake a systematic literature review of MAM processes for the aerospace/aeronautic sector focusing on energy and material efficiency. Relevant literature was classified and discussed based on the life cycle stages at which resource efficiency strategies for MAM were identified: (1) product design; (2) material development and sourcing; (3) processes development, control, and optimization; (4) end-of-life extension and circular economy. Results highlight the key factors required to optimize MAM and the relevance of assessing its environmental impact compared to conventional manufacturing. Material and energy efficiency vary significantly between different MAM processes due to several factors directly linked to the process but also associated with the supply chain, e.g. electricity mix or material sourcing. Further research could explore new trends in technological development for circularity or multi-material MAM. •Metal Additive Manufacturing (MAM) as an enabler of resource efficiency in aeronautics.•Efficiency strategies were identified at different levels: design, material, process, and end-of-life.•Key factors affecting MAM overall performance were identified.•Material and energy efficiency vary significantly between different MAM processes.