Expanding the horizons of metal additive manufacturing: A comprehensive multi-objective optimization model incorporating sustainability for SMEs

Metal Additive Manufacturing (MAM) has seen significant growth in recent years, with sub-processes like Metal Material Extrusion (MEX) reaching industrial readiness. MEX, known for its cost-effectiveness and ease of integration, targets a distinct market segment compared to established high-end MAM processes. However, despite technological improvements, its overall integration into the industry as a viable manufacturing technology remains incomplete. This paper investigates the competitiveness of MEX, specifically its integration into the supply chain and the implications on cost and carbon emissions. Utilizing real-world data, the research develops a multi-objective optimization (MOO) model for a four-echelon supply chain including suppliers, airports, production facilities, and customers. The optimization model is combined with a previously developed cost model for MEX to optimize facility location in Norway using the NSGA-II algorithm. Employing a case study approach, the paper examines the production of an industrial part using stainless steel 17-4PH, detailing concrete process costs and system-level costs across four different production scenarios: 10, 100, 1,000, and 10,000 parts. The findings indicate MEX’s potential for cost-effective production at low and diversified volumes, supporting the trend towards customization and manufacturing flexibility. However, the study also identifies significant challenges in maintaining competitiveness at higher production volumes. These challenges underline the necessity for further advancements in MEX technology and process optimization to enhance its applicability and efficiency in larger-scale production settings.