Aluminum Laser Additive Manufacturing: A Review on Challenges and Opportunities Through the Lens of Sustainability

The manufacturing sector is a major contributor to global energy consumption and greenhouse gas emissions, positioning sustainability as a critical priority. Aluminum, valued for its lightweight and recyclable properties, plays a vital role in advancing energy-efficient solutions across transportation and aerospace industries. The processing of aluminum alloys through laser-based powder bed fusion of metals (PBF-LB/M), a cutting-edge additive manufacturing technology, enhances sustainability by optimizing material usage and enabling innovative lightweight designs. Based on the published literature, the present study analyzed the ecological impacts of aluminum PBF-LB/M manufacturing through life cycle assessment, circular economy principles, and eco-design strategies, identifying opportunities to reduce environmental footprints. The study also stated the critical challenges, such as the high energy demands of the aluminum PBF-LB/M process and its scalability limitations. Potential sustainable solutions were discussed starting from powder production techniques, as well as optimized processes and post-processing strategies. By adopting an interdisciplinary approach, this research highlighted the pivotal role of PBFed aluminum alloys in achieving sustainable manufacturing goals. It provided actionable insights to drive innovation and resilience in industrial applications, offering a roadmap for balancing environmental stewardship with the demands of high-performance standards.