LCA and LCC of wire arc additively manufactured and repaired parts compared to conventional fabrication techniques

Multi-material wire arc additive manufacturing (MM-WAAM) exhibits considerable promise for producing functional gradient materials, components with complex design, and enable a more local supply chain. However, it is still to be determined for which industrial applications MM-WAAM present more benefits than conventional production routes both in terms of environmental and economic impacts. This study undertook a comprehensive cradle-to-grave assessment encompassing two distinct metallic components, manufactured via either additive manufacturing (AM) or conventional fabrication procedures. One of those is a repair case of a forging die, and the other is the production of an industrial tool. Analysis outcomes manifestly revealed pronounced benefits associated with MM-WAAM for these components. For instance, the utilization of MM-WAAM in crafting an optical fiber case injection mould tool yielded energy consumption reduction, attributed to enhanced conformal cooling channels. Additionally, the repair of a forging die via MM-WAAM showcased the potential to curtail new scrap generation during post-processing, prolonging tool lifespan. This study conclusively shows the application-specific nature of MM-WAAM's favourability over traditional processes, thereby offering valuable insights for strategic implementation.