A DYNAMIC LIFE CYCLE ASSESSMENT FRAMEWORK FOR GAS TURBINE PACKAGE COMPONENTS USING SUSTAINABLE MATERIALS AND ROBOTIC ADDITIVE MANUFACTURING

The industrial sector accounts for 30% of global greenhouse gas emissions and 37% of global energy consumption, necessitating sustainable solutions in heavy manufacturing. This research explores the use of sustainable materials and Additive manufacturing (AM) for gas turbine (GT) package components, specifically the baseplate and air filter module. Traditional steel-based components are replaced with wood-plastic composites and eggshell-filled concrete, produced through robotic AM. A Life Cycle Assessment (LCA) was conducted using OpenLCA and secondary data from the Ecoinvent database, employing a cradle-to-gate framework to evaluate Global Warming Potential (GWP), resource depletion, and toxicity. Initial results indicate a 40% reduction in GWP compared to steel-based components Building on these findings, a dynamic unit process model for Fused Deposition Modeling (FDM) is introduced. Unlike static LCA models, this approach uses time resolved energy consumption and material flow data to enable scenario-based impact assessments. Python-based tools further streamline LCA workflows, allowing for rapid recalculation of results when print parameters or materials change. By integrating LCA into the early design phase, this research demonstrates a pathway toward more environmentally responsible manufacturing and offers a scalable framework adaptable to a wide range of AM processes.