EOS, a manufacturer
of laser sintering systems, in collaboration
with EADS Innovation Works (IW), has started work on a study to understand the
potential of the direct metal laser sintering (DMLS) process to generate
savings in the use of energy and raw materials. This will help to develop a new
range of manufacturing technologies that will integrate sustainability relevant
aspects into products and product manufacturing.

By capitalizing on
the benefits the DMLS process offers, including the net-shape technology to
generate weight-reduced structures, along with the low use of raw materials,
DMLS technology has great potential to contribute to sustainable development in
manufacturing.

A previous study
conducted by EADS IW showed that although the use of energy during the
manufacturing phase could not compare with conventional manufacturing
processes, energy consumption during the use-phase of aircraft components
dropped significantly. Indeed the DMLS technology unlocks structural
optimization, leading to weight reduction of the components, and thus fuel and
carbon dioxide emissions reduction.

In parallel, EOS
carried out a Product Carbon Footprint (PCF) calculation of one kilogram of
sintered material. The findings supported EADS IW’s research, as they showed
that the greatest impact on reducing carbon dioxide emissions and
energy consumption was to be found during the use-phase of laser-sintered components.
It further identified the most important drivers of energy consumption along
the B2B value chain, particularly around the supply of raw materials and the
use of cooling systems. It was while comparing data that EADS IW and EOS agreed
to carry out a collaborative environmental study.

Technologies
applied to aerospace normally have to go through a nine-step process called TRL
(Technology Readiness Level) before they are ready to undergo qualification.
For each TRL review, the evolution in maturity of a technology is measured in
terms of performance, engineering, manufacturing, and operational readiness as
well as value and risk and sustainability/environment. The latter is a new
criterion linked to EADS Group’s eco-efficiency vision in conjunction with EADS
IW.

Following on from
the original study, EADS IW and EOS will now complete a full life cycle assessment (LCA)—covering energy consumption, material use, carbon dioxide
emissions, and use of hazardous material—benchmarking an optimized design for
use with EOS’ next-generation platform EOSINT M 280 metal system. Results are
expected to show improvements in sustainable performance not only on the
component, but also on its manufacturing.

The
joint EOS/EADS IW project will be carried out throughout the rest of the year.
More detailed results will be made available towards the end of 2011.

EOS, www.eos.info