Cradle-to-Gate Life Cycle Analysis of Origami-Based Sheet Metal for Automobile Parts

The sustainability of sheet metal parts often has multiple facets depending on the phase under consideration. The work presented in this paper focuses on cradle-to-gate Life Cycle Analysis (LCA) of the Origami-based Sheet Metal (OSM) folding process. OSM is an emerging fabrication technique that utilizes the principle of folding sheet metal parts by creating Material Discontinuities (MD) along the bend line. MD enables sheet metal folding (i.e., bending) with minimal force requirements and machinery. The anticipated reduction in force and machinery will result in a reduction in the required manufacturing energy. In addition, the OSM has less dependency on dies and shape-dedicated equipment. Hence, the cost associated with sheet metal parts development is reduced. This study attempts to establish the environmental impacts of the OSM for sheet metal parts by utilizing cradle-to-gate life cycle analysis. Environmental impacts of OSM are highlighted by comparing the OSM with the conventional stamping process. In the LCA, consumed energy and emissions are considered environmental impact indicators. Energy and emissions data are collected from published literature, machinery manuals, and available empirical models for energy consumption. A case study of a vehicle floor panel is presented as an example. Finite element analysis (FEA) is employed to achieve a more accurate energy estimation since the LCA inventory data displays a significant discrepancy. The findings of this study reveal that OSM requires less energy and produces fewer emissions than the stamping process.