The sustainable production of components has to deal with a large number of challenges. In addition to the high accuracy in series production, production costs have always played a major role. If sustainability and the conservation of resources are to be taken into account, it will be necessary to break up conventional thinking structures and discover new ways of production. For the extraction of raw materials from which later products are to be manufactured, a large amount of energy is usually necessary.
The elaborately obtained raw materials must therefore be protected and further processed in an economical way. If, for example, a cutting process is then used which removes material with additional energy by, for example, drilling, turning, grinding, honing or sawing, clippings are produced in which a lot of primary energy has been bound – the material now ends up as waste. Therefore, “classical” manufacturing processes were also called subtractive processes.
Although these chips could also be processed, although again this costs energy. Economical use of raw materials is hardly possible in this way. Between subtractive processes and additive processes, such as 3D printing, there are casting processes, which, due to the complexity in mould design and mould planning, are only economically applied in large series. At this point, SLS 3D printing scores points, because as an “additive” manufacturing process, it only welds, and therefore only uses, those raw materials which are needed for the later component.