Optimizing Additive Manufacturing of Superalloys for Sustainable Prototyping

This chapter explores sustainable prototyping through additive manufacturing (AM) of superalloys, particularly in aerospace and energy sectors. It begins with an overview of superalloy material science and its environmental implications, then examines AM technologies that offer efficiency and reduced ecological impact. By customizing AM parameters and applying lifecycle assessments, both performance and sustainability can be optimized. Topology optimization enhances material efficiency, while strategies like waste minimization and powder recycling support circular economy goals. The chapter emphasizes scalability and evolving standards as key factors for broader industry adoption, supported by case studies showing real-world environmental and economic benefits. Future innovation paths, including AI-integrated manufacturing and eco-friendly alloy development, are discussed as part of a holistic approach that unites technical advancement with ecological responsibility.