Life cycle assessment of lattice structures: Balancing mass saving and productivity

Additive Manufacturing has revolutionized manufacturing processes, offering design flexibility and advances in various applications. The integration of lattice structures into lightweight designs has attracted attention due to their ability to optimize properties such as stiffness, strength and energy absorption. This paper explores the trade-off between mass reduction and productivity while evaluating the environmental sustainability of lattice structures manufactured with Laser-based powder bed fusion for metals Using Life Cycle Assessment, two design variants for an automotive component are compared: a topologically optimized version with a solid bulk section, and a second design with lattice structures for additional weight reduction. Experimental measurements and a detailed analysis of the laser strategy were performed to build the Life Cycle Assessment inventory. The integration of lattice structures allowed a weight reduction of 6 %, but resulted in a significant decrease in productivity and a higher environmental impact. Surprisingly, lattice geometries, often perceived as green solutions, can have negative sustainability implications due to longer manufacturing times and impact of auxiliary equipment. Successful implementation of environmentally sustainable designs requires a balance between mass reduction and productivity while addressing potential environmental consequences.