Eco-Design for Additive Manufacturing (EcoDAM)

The EcoDAM (Eco-Design for Additive Manufacturing) project presents a comprehensive framework aimed at enhancing the environmental sustainability of metal additive manufacturing (AM) processes. Recognizing the complex interdependencies between material selection, manufacturing technologies, and lightweight design, the framework integrates four key steps: sustainable technology selection, lightweight design optimization, and a two-phase parametric life cycle assessment (LCA) involving both objective function formulation and constraint definition. Innovative methodologies such as function-oriented patent analysis, topological and lattice structure optimization, and parametric LCA modelling are employed to systematically evaluate and minimize environmental impacts throughout the AM product lifecycle. A case study based on Ti6Al4V connecting rod produced by laser powder bed fusion demonstrates the application of the framework, resulting in more than 50% weight reduction and improved sustainability performance. Key parameters, such as cell size and wall thickness of gyroid lattice structures, are optimized using finite element modelling simulations, while LCA constraints are formulated using experimental and literature-based data. The framework’s modular design allows for industrial integration using commercial tools, enabling scalable, data-driven, and environmentally informed decision-making in AM. EcoDAM thus contributes a robust methodology for advancing circular economy goals in industrial AM.