ABSTRACT
Objective: This study intends to perform a theoretical analysis of Additive Manufacturing applicability and integration with Solid Waste Management practices.
Theoretical Framework: The main concepts and theories in Industry 4.0, Additive Manufacturing, Solid Waste Management, Cleaner Production, Reserve Logistics stand out, providing a solid basis for understanding the investigation context.
Method: This study investigated two of the largest sustainable companies that develop green products and resources for Additive Manufacturing uses operating in the Brazilian market. The information was collected from portals, reports of results, processes, and green manufactured products, according to literature.
Results and Discussion: The study results that Additive Manufacturing implementation generated significantly less waste due to technology applied and its usage of green and efficient inputs.
Research Implications: This research provides insights into how the results can be applied in Additive Manufacturing Field. These implications could encompass the waste management area and the recycling methods for polypropylene residues.
Originality/Value: This study contributes to the literature by analyzing the relationship between additive manufacturing and waste management with the Industry 4.0 concepts, showing additive manufacturing as an alternative way of more sustainable production.
Keywords: Additive Manufacturing, Waste Management, Environmental Impacts, 4.0 Industry.
RESUMO
Objetivo: Este estudo pretende realizar uma análise teórica da aplicabilidade e integração da Manufatura Aditiva com as práticas de Gestão de Resíduos Sólidos.
Estrutura teórica: Destacam-se os principais conceitos e teorias da Indústria 4.0, Manufatura Aditiva, Gestão de Resíduos Sólidos, Produção mais Limpa, Logística de Reserva, fornecendo uma base sólida headnote a compreensão do contexto da investigação.
Método: Este estudo investigou duas das maiores empresas sustentáveis que desenvolvem produtos e recursos verdes headnote usos de Manufatura Aditiva operando no mercado brasileiro. As informações foram coletadas de portais, relatórios de resultados, processos e produtos manufaturados verdes, de acordo com a literatura.
Resultados e discussão: Os resultados do estudo mostram que a implementação da manufatura aditiva gerou significativamente menos resíduos devido à tecnologia aplicada e ao uso de insumos ecológicos e eficientes.
Implicações da pesquisa: Esta pesquisa fornece insights sobre como os resultados podem ser aplicados no campo da manufatura aditiva. Essas implicações podem abranger a área de gerenciamento de resíduos e os métodos de reciclagem de resíduos de polipropileno.
Originalidade/valor: Este estudo contribui headnote a literatura ao analisar a relação entre a manufatura aditiva e a gestão de resíduos com os conceitos da Indústria 4.0, mostrando a manufatura aditiva como uma forma alternativa de produção mais sustentável.
Palavras-chave: Manufatura Aditiva, Gestão de Resíduos, Impactos Ambientais, Indústria 4.0.
RESUMEN
Objetivo: Este estudio pretende realizar un análisis teórico de la aplicabilidad e integración de la Fabricación Aditiva con las prácticas de Gestión de Residuos Sólidos.
Marco Teórico: Destacan los principales conceptos y teorías en Industria 4.0, Manufactura Aditiva, Gestión de Residuos Sólidos, Producción más Limpia, Logística de Reserva, proporcionando una base sólida headnote la comprensión del contexto de investigación.
Método: Este estudio investigó dos de las mayores empresas sostenibles que desarrollan productos y recursos verdes headnote usos de Fabricación Aditiva que operan en el mercado brasileño. Las informaciones fueron recogidas de portales, informes de resultados, procesos y productos fabricados verdes, de acuerdo con la literatura.
Resultados y discusión: El estudio concluye que la implantación de la Fabricación Aditiva generó una cantidad significativamente menor de residuos gracias a la tecnología aplicada y al uso de insumos ecológicos y eficientes.
Implicaciones de la investigación: Esta investigación proporciona implicaciones sobre cómo pueden aplicarse los resultados en el campo de la Fabricación Aditiva. Estas implicaciones podrían abarcar el área de gestión de residuos y los métodos de reciclaje de residuos de polipropileno.
Originalidad/Valor: Este estudio contribuye a la literatura analizando la relación entre la fabricación aditiva y la gestión de residuos con los conceptos de Industria 4.0, mostrando la fabricación aditiva como una vía alternativa de producción más sostenible.
Palabras clave: Fabricación Aditiva, Gestión de Residuos, Impactos Ambientales, Industria 4.0.
1 INTRODUCTION
According to Schwab (2016), there are currently four industrial revolutions, the term "revolution" refers to radical changes that cause modifications in the economic system and social structures through technological advances and new ways of understanding the world.
The industrial revolutions can be identified through their main milestones and innovations. The first revolution, which happened in the mid-18th and 19th centuries, brought innovations in the construction of railroads and the creation of the steam engine. The second, dated between the end of the 19th century and the beginning of the 20th, had as milestones the mass production, the arrival of electricity, and the use of the assembly line. The third, also called the digital revolution, started in the 1960s and was characterized by the development of semiconductors, large and personal computers, and the internet. The fourth and current revolution, entitled "Industry 4.0", is characterized by a more omnipresent and mobile internet, more powerful and smaller sensors, artificial intelligence, cyber-physical systems, additive manufacturing, and machine learning.
According to the Institute of Applied Economic Research - IPEA (2021) based on the report "What a Waste 2.0", about 2.01 billion tons of Municipal Solid Waste (MSW) are generated annually by the entire world population, and there is an expectation that in 2050 will reach 3.40 billion, an increase of almost 70%. The impacts generated by the production processes are significantly harmful to all living beings, and because of this, some countries are increasingly seeking technologies and innovations in order to minimize them.
One of the manufacturing modes that helps the reduction and management of solid waste generated in the production process is additive manufacturing because one of the additive manufacturing advantages is the little material waste and the efficient energy use VOLPATO et. al (2017). Note that many times, the material that is spent to manufacture a component is equivalent to the item material volume.
2 THEORETICAL FRAMEWORK
2.1 INDUSTRY 4.0
Industry 4.0 is a concept that integrates society with the digital environment, according to Quintino et al. (2019), initially, its focus was directed to manufacturing activities, however, its concepts have been expanded and developed for the areas of agriculture and services, for example.
For Sacomano et al. (2018) the 4.0 Industry can be defined by three-element groups: Base or fundamental elements, that define and ground the technological basis and the concept of Industry 4.0; Structure elements, that make it possible to build Industry 4.0 applications and Complementary elements, which by themselves don't characterize the application as Industry 4.0 but expand its action possibilities.
Therefore, according to Sacomano et al. (2018), the basic elements are cyber-physical systems, the internet of things, and the internet of services; the structuring elements are automation, machine-to-machine communication, artificial intelligence, big data analytics, cloud computing, system integration, and cybersecurity; the complementary elements are RFID tags, QR code, augmented reality, virtual reality, and additive manufacturing (figure 1).
Industry 4.0, as per Ynzunza-Cortés et al. (2017), transforms and proposes new visions in smart factories, since in this model, machines must be able to communicate with each other, transmit information, and perform actions. They must also have a high arrangement of sensors to collect large amounts of data, which can be of any type, and is primarily stored in the cloud, helping the storage, and processing of these large data amounts that are transmitted all the time.
Ynzunza-Cortés et al. (2017) understand, the association of the internet of things to the process occurs, enabling greater participation of those involved (customers, employees, among others) in manufacturing decision process, quality, and customization of products. Throughout the process one should consider the cyber security of the system to provide a safe and reliable environment to transmit and provide the information to all involved.
2.2 ADDITIVE MANUFACTURING
Additive manufacturing is one of the newest forms of technology that's increasingly being employed in manufacturing processes. Also known as three-dimensional printing, it had its first working 3D printer created by Charles W. Hull of 3-D System Corp, a review in the research work by Vardhan et al. 2014 (described by Silva et al., 2018).
As explained by Almeida (2019) additive manufacturing "involves the production of parts from overlapping material layers, usually obtained from cartridges with plastic material in circular section wire form that are heated in the 3D printer head". Such a printing process deposits layers upon layers of the raw material, which are defined by means of 3D design software that transmits to the printer all the instructions to carry out the entire process.
The study by Karapatis et. al. 1998 (explained by Aires et al., 2019) defines the production processes in additive manufacturing basically following the same steps as conventional manufacturing, they are:
a) elaboration of the desired model, design, or objective virtually by means of CAD software, representing it on a solid surface in 3D;
b) converting the model format to a format recognized by printers, the standard format recognized by additive manufacturing technologies being the STL language (Standard Tessellation Language or Standard Triangulation Language), so that, later, the model to be produced is sliced with information from each layer;
c) machines with their own software, to ensure the number of parts to be produced, ideal size, orientation, and positioning, then the part file is converted into STL format and sent to this software;
d) parameters of the additive manufacturing printer contain the information that must be configured before production starts, such as layer thickness, quantity, and so on;
e) sending the file to the printer to start building the part;
f) once the construction is finished, the piece must be carefully removed; and
g) post-processing is started after the part has been taken out of the printer to remove dirt from the material used, however, in some technologies, additional treatment is required such as the application of some substances on the part.
The following figure 2 is an example that represents the additive manufacturing production process:
Additive manufacturing's fundamental characteristics refer to the reduction in steps and manufacturing processes of a given good, savings in raw materials, energy, etc., less waste generated, lower production cost, and, consequently, fewer environmental impacts (Juanhuan et al., 2019). An automated facility considerably minimizes human intervention during the part manufacturing process (Volpato & Carvalho, 2017).
And these manufacturing technologies have become possible through the integration of traditional processes such as powder metallurgy, extrusion, welding, machining, besides other technologies such as high precision motion control, inkjet printing systems, laser, electron beam technologies, and the development of materials suitable for each of these processes.
2.3 SOLID WASTE MANAGEMENT
The Solid Waste Policy (PNRS) described by the present LAW No. 12,305, in the Brazilian constitution of August 2, 2010, defines solid waste as:
Material, substance, object or discarded goods resulting from human activities in society, to whose destination is proceeded, proposed to proceed or is obliged to proceed, in solid or semi-solid states, as well as gasses contained in containers and liquids whose particularities make it infeasible to discharge them into the public sewage system or bodies of water, or require solutions that are technically or economically unfeasible in view of the best technology available (Brazil, 2010).
The classification of solid waste, ABNT Standard NBR 10004:2004 reports that such classification involves the process or activity identification that gave rise to the waste and its constituents and characteristics, and the comparison of these constituents with waste and substance lists whose impact on health and the environment is known. The same standard classifies the waste according to its potential risks to the environment and public health, according to the following classes:
a) class I waste - Dangerous;
In this class the waste denotes danger, presenting characteristics such as flammability, corrosivity, reactivity, toxicity, and pathogenicity.
b) class II waste - Non-hazardous.
The non-hazardous waste classification, it is divided into two classes: Class II A waste - Noninert, with biodegradability, combustibility, or water solubility as properties and Class II B waste - Inert, when submitted to a dynamic and static contact with distilled or deionized water, at room temperature, does not have any of its constituents solubilized at concentrations above the water potability standards, except for its aspect, color, turbidity, hardness, and taste.
Solid waste can also be classified according to its origin, explained by Tchobanoglous and Kreith 2002 (whose explanation can be obtained by Deus et al., 2015), is divided into Residential; Commercial; Institutional; Construction and demolition; Municipal services; Treatment plants; Industrial; and Agriculture.
When adopting the PNRS use in solid waste management in Brazil, it's necessary to follow a priority order present in article 9 in Brazilian law No. 12.305, of August 2, 2010, and that can be visualized in figure 3.
Veiga (2016) states that the hierarchy establishes as an initial foundation the non-generation; the reuse; the recycling; the waste recovery, which can include the energy recovery from them; and finally, the waste final disposal environmentally appropriate. However, the author warns that to accomplish such a structure is necessary to be aware of the distinction between waste and rejects, the latter defined as "solid waste that, after exhausting all possibilities of treatment and recovery [...], have no other possibility but the final disposal environmentally appropriate" (Brazil, 2010).
Finally, Xavier 2013 (analyzed by Pontes, 2017) highlights that solid waste management is a solution for public health through pollution control, the sizing of treatment facilities, and the impacts of landfill construction.
2.4 CLEANER PRODUCTION
According to Henriques and Quelhas 2007 (cited in Bacarji et al., 2009), the Cleaner Production systems are circular and use fewer materials, less water, and less energy. In this way, the resources go through the production and consumption cycle at a slower pace.
The principles of Cleaner Production look for the real need of the product and different ways to satisfy or reduce the needs found. The basic principle of Cleaner Production methodology is to eliminate pollution during the production process, not at the end.
Other principles of Cleaner Production (CP) are energy and materials savings, adoption of cleaner production processes and technologies, reduction or elimination of waste, preserving the health of employees and the environment, improving processes and products aiming at waste reduction and the best use of resources.
The cleaner production system (CP) implementation promotes several benefits, which are highlighted by the United Nations Industrial Development Organization (UNIDO) that are: increased productivity, better environmental performance, and reduced environmental impact of the entire product life cycle. The cycle for the implementation of the system consists of analyzing the current system situation, defining in conjunction with all system participants' objectives and priorities and policy development.
2.5 RESERVE LOGISTICS
According to Rogers and Tibben-Lembke 1999 (cited in Oliveira et al., 2020), reverse logistics is the process of planning, implementing, and controlling the efficient and cost-effective flow of raw materials, in-process inventory, finished products, and related information from the point of consumption to the point of origin, with the goal of value recovery or proper disposal for waste collection and treatment.
In Brazil, this concept was initially established through the National Policy for Solid Waste (PNRS), Law 12.305/2010. From this policy, it was defined the need to hold waste generators, the government, manufacturers, distributors, and importers jointly responsible.
The shared responsibility according to SINIR (National Information System on Solid Waste Management) highlights that each part of society has its role so that the application is done correctly, where:
● the consumer is responsible for delivering the waste under the conditions and places established by the reverse logistics systems;
● the private sector is responsible for the correct management of solid residues, reincorporation in the productive chain, product innovations that bring socio-environmental benefits, rational use of materials, and pollution prevention;
● the public power is responsible for the supervision of the process, raising awareness, and educating the citizens.
In recent years there has been a great stimulus for companies to adhere to reverse logistics due to its importance, both for suppliers and consumers. Rodrigues (2002) highlights the five main reasons for the stimulus of reverse logistics are ecological sensitivity, legal pressures; reduction of the product life cycle; differentiated image; cost reduction.
3 METHODOLOGY
This work is a development of a study about the relationship between additive manufacture, using as a basis the material published by Braskem and HP in digital media and the solid waste management concepts. For the execution of this study, exploratory bibliographic research was conducted, which according to Sampieri, Collado and Lucio (2013) is the ideal study method for little in-depth themes or problems, without the construction of well-developed and innovative relationships.
Therefore, it was elaborated with a deepening knowledge about the most recent technologies, waste solid management, and additive manufacture methods for identifying and analyzing the ideal procedures in additive manufacture waste management.
The methodology utilized is the case study, following Yin (2015), an empirical investigation in which the investigators consider a specific point, retaining the real-world perspective in one focus. The study originated in knowledge searching in relation to social phenomena. It's necessary in this methodology type, to build up the planning, the collection, and the analysis of the data obtained, being able to differentiate between single or multiple case studies, and also the differentiation between the quantitative and qualitative approach.
For the realization of this study, the qualitative approach was adopted, and the cases studied are Braskem and HP's additive manufacturing products. Identifying how the waste disposal and treatment should be carried out in the parts manufacturing process.
4 RESULTS AND DISCUSSIONS
4.1 BRASKEM'S ADDITIVE MANUFACTURING
The Braskem S.A. is a company founded in August 2002 by the integration of six companies Odebrecht Organization and Mariani Group. Their activities are inserted in the chemical and petrochemical sector, being the reference of thermoplastic resin production in the Americas, the only integrated petrochemical of the first and second generation of thermoplastic resins in Brazil, and the greatest polypropylene producer in the United States (Braskem, 2021b).
The company is one of the pioneers in the sustainable products field, with major contributions to the creation of the sustainable solution that aims at improving people's lives, including in its portfolio, the green polyethylene, which is a product produced from sugar cane with 100 % renewable origin (Braskem, 2021b).
The practices related to sustainable development are applied to its production processes, with relevance to Circular Economy, which focuses on solutions reducing environmental impact, generating value and contributing to sustainable development and in the SDG Compass methodology that has the purpose of assessing the caused impacts based on the Sustainable Development Goals of 2030 agenda.
To produce materials according to additive manufacturing, Braskem produces two polypropylene filament types, the FL100PP and FL105PP, which are part of the company's portfolio of innovative products. The first has the characteristics of low density and high fatigue resistance, offering a balance between strength and impact resistance. The second is designed to provide superior dimensional accuracy by giving a balance between impact resistance and dimensional accuracy. Both feature moisture resistance for use in Cast Filament Fabrication, allowing the production of watertight, lightweight, and chemical-resistant parts.
4.2 MANAGEMENT OF BRASKEM'S WASTE AND DISCARDS
Braskem's polypropylene filament residues are not hazardous in toxicity terms and are classified as a non-hazardous chemical product, according to ABNT 14725-2. Furthermore, there are no contamination risks for soil and water bodies, and the greatest potential threat is the polypropylene materials ingestion in small shapes such as pellets.
In the disposal, it's recommended to avoid dumping the polypropylene and the packaging into sewers or treating them as common waste - the major problem of the material discarded from additive manufacturing is choosing where it should be disposed of. Therefore, it is needed to minimize sending polypropylene waste to landfills and water bodies, reusing the waste that didn't suffer significant chemical and physical damage in the beginning of the production chain as an input for the new polypropylene filaments manufacturing.
Linked to the Circular Economy methodology, some goals were set with the reducing waste generation objective in their production lines. The strategy applied has the intention of intensifying the Carbon-Neutral Circular Economy, which establishes a carbon neutrality goal until 2050 and a greenhouse gas emissions reduction by 15 % until 2030, going from 10.8 million tons of CO2 in 2019 to 9.2 million at the established period end (Braskem, 2021a).
Therefore, Braskem involves a systemic approach in order to maintain the continuous resources flow and carry out the treatment of the plastic waste generated in the production cycle. In this way, the company performs mechanical sorting and recycling and has a technology improvement process for chemical recycling, transforming plastic waste into chemical inputs, fuels, or raw materials for the manufacture of new plastic products.
Braskem has also been involved in the value and supply chain actions of their products in order to optimize and participate in pertinent solutions to strengthen the circular economy strategy, crossing technical and logistical barriers to ensure the destination of the material to be recycled in quantity and quality.
4.3 HP'S ADDITIVE MANUFACTURING
The Hewlett-Packard Company (HP) has in its portfolio several types of machinery related to additive manufacturing. The HP Labs help to advance the pioneering technologies of printing and imaging, proposing to unleash the manufacturing creativity and revolutionize the processes for product creation, conciliating them with sustainable practices to generate fewer environmental impacts (HP, 2021b).
The HP Jet fusion 5200 printer, one of the leading printers in the HP portfolio, has compatibility with a variety of polymers compounds, which provides a variety of distinct characteristics for the final product (HP, 2021a).
However, the technology adopted only allows the insertion of powder compounds regardless of the type of material chosen to create the product. Based on HP's selection catalog, the polypropylene powder use was chosen as standard, because it provides the final product with characteristics ranging from reasonable to good, with a few negative highlights described in figure 4.
This material is highly recyclable and can be turned into polypropylene powder again in the HP recommended facilities. Additionally, it highlights the known polypropylene characteristics, such as non-toxicity, and low dangerousness in handling. It is also worth mentioning that such material is safe in the emission of ultrafine, large particles, and in the fine dust emission, the operator handles the machine in the recommended way, being the biggest danger then, the polypropylene or the manufactured part ingestion.
4.4 HOW MJF TECHNOLOGY WORKS
HP's technology for manufacturing its products is called Multi Jet Fusion (MJF), a high-speed synchronous architecture that creates parts layer by layer. HP Multi Jet Fusion is a 3D printing process that bases a mix of technologies such as Binder Jetting, PolyJet, and Selective Laser Sintering (SLS) in the production of parts with optimized production time (HP, 2021c).
The MJF technology provides 3D printing in color, which facilitates the visualization of the creations by the designers, proposes a reduction in the weight of the final piece, as well as optimizes and improves the performance of the machines and the production itself. The 3D Printer with MJF has advantages like a much faster production speed than other existing technologies on the market, and it counts with the process automation. The disadvantage is its high commercial price, generally not very accessible.
The analyzed machinery of the HP Jet fusion 5200 series consists of the 3D Printer, the Print build unit, the Processing station; and the Natural cooling unit.
According to the company, these products make the workflow streamlined and can stimulate growth and increased production.
The process begins with the prototype development by the software "SmartStream 3D", which has as its objective the virtual creation of the parts that will be manufactured. The prototype may or may not be forwarded to the "HP 3D Process Control" software, which is responsible for keeping control of the continuous processes, in case it is necessary to repeat the dimensions quickly and accurately for the manufacturer of the new part (HP, 2019a).
Then, the build unit is sent to the "3D HP Jet fusion 5200" processing station, where the loading is performed, and fresh and reused materials are mixed in the build unit itself.
Soon after, it's necessary to assemble the build unit with a printer and perform the prepress checks on it, when they are complete you can start the production process, which can be tracked and managed via the "HP 3D Center" software.
After finishing the printing process, it performs the printed material cooling either by inserting the build unit into the processing station or by using the HP Jet Fusion 3D natural cooling unit. After being cooled, the material is removed from its package, and unused waste is recovered for building new products.
4.5 HP WASTE AND DISPOSAL MANAGEMENT
HP reports in the HP Jet fusion 5200 Series 3D printer manual that the disposal of parts and waste generated during the printing process should be done according to local, state, and federal regulations (HP, 2019).
The manual also states that certain printed parts can be recycled for use beyond 3D printing and informs about marking these pieces with a plastic marking code that complies with ISO 11469, encouraging recycling.
The company has a recycling program for printer supplies, whose information is available on their website. In this program you can recycle the following items: HP printheads; Material cartridges; Printhead cleaning roller; Lamps; and Filters.
5 CONCLUSION
The environmental issue related to additive manufacturing is a topic to be considered because it has great importance given that adopting sustainable practices is an increasing necessity. This article had the objective of analyzing the relationship between additive manufacturing and waste management and, to this end, analyzed companies that are proactive in the sustainable issue, which are using or are moving towards the application of additive manufacturing in the production process.
The technology application changes the methodology and production planning because the part is planned, developed in software, and prototyped through 3D printers with pre-established sustainable requirements, unlike conventional manufacturing that produces and then treats the waste generated, as in the case of machining, casting, and other techniques.
Using the concepts of Cleaner Production, the additive manufacturing implementation improves the material efficiency, reducing the waste and the excess in the common processes in the industry. In those analyzed cases, it's possible to observe the efficiency of the system.
Compared to conventional manufacturing, additive manufacturing generates significantly fewer wastes, uses innovative raw materials, and minimizes the need for innumerable pieces of equipment. Sustainable design use considers what impacts can be generated, how leftovers will be reused, and how waste and rejects will be managed before production begins.
Reverse logistics is widely related to the HP and Braskem cases. In the first case, the company implemented a way to reuse the materials and components of the 3D printer process, transforming them into new products to new additive processes. In the second, the company has methods to use the polypropylene wasted in an additive process in new filaments and pellets, recycling them and establishing a logistic cycle for this material.
Another important factor in 3D printing is the energy savings in production because the products go through a rigorous analysis through software and tests before being produced.
Therefore, the study results were satisfactory and highlighted the relationship importance between additive manufacturing and waste management for better performance, precision, and efficiency in the use of resources, as well as the innovative concepts and innovations pertinent to the technology's application.
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Abstract
Objective: This study intends to perform a theoretical analysis of Additive Manufacturing applicability and integration with Solid Waste Management practices. Theoretical Framework: The main concepts and theories in Industry 4.0, Additive Manufacturing, Solid Waste Management, Cleaner Production, Reserve Logistics stand out, providing a solid basis for understanding the investigation context. Method: This study investigated two of the largest sustainable companies that develop green products and resources for Additive Manufacturing uses operating in the Brazilian market. The information was collected from portals, reports of results, processes, and green manufactured products, according to literature. Results and Discussion: The study results that Additive Manufacturing implementation generated significantly less waste due to technology applied and its usage of green and efficient inputs. Research Implications: This research provides insights into how the results can be applied in Additive Manufacturing Field. These implications could encompass the waste management area and the recycling methods for polypropylene residues. Originality/Value: This study contributes to the literature by analyzing the relationship between additive manufacturing and waste management with the Industry 4.0 concepts, showing additive manufacturing as an alternative way of more sustainable production.