Sustainable 3D Printing: How Eco-Friendly is 3D Printing Really?

In a world increasingly critical of manufacturing processes and their environmental impact, the question arises: how sustainable is 3D printing actually? The answer is more nuanced than a simple yes or no, but the trend is positive.

At 3Dennis, we take sustainability seriously. In this article, we examine the real environmental benefits of 3D printing and how we contribute to a greener future.

Less material waste

The most direct environmental benefit of 3D printing lies in the production process itself. Where traditional manufacturing removes material (milling, turning, drilling), 3D printing only builds what’s needed.

Additive versus subtractive

With CNC milling, you start with a block of material and remove everything that doesn’t belong to the final product. Depending on the shape, this can be 50% to 90% of the material ending up as waste.

3D printing works the opposite way. You only use material that actually ends up in the final product, plus minimal amounts for support structures where needed. The difference in material efficiency is enormous.

Practical example

A complex mechanical part we recently made for a client would generate 800 grams of aluminum waste with traditional production. With 3D printing, we used 120 grams of PETG, of which less than 10 grams was support material that could be recycled.

Local production eliminates transport

Many products travel halfway around the world before reaching the end user. Parts made in China, shipped to ports, distributed throughout regions - the carbon footprint of transport is significant.

Production close to the customer

3D printing makes local production economically feasible. We produce in the Netherlands for Dutch customers. No container ships, no long truck transports. Most deliveries are within 100 kilometers of our production point.

This concept, often called “distributed manufacturing,” becomes increasingly relevant as 3D print technology improves. The factory of the future might be just around the corner.

On-demand production

Traditional manufacturing requires stockpiling. Companies produce large batches to achieve economies of scale, leading to overproduction and ultimately waste when products don’t sell.

With 3D printing, you produce what you need, when you need it. No warehouses full of unsold inventory, no products discarded after years. This on-demand model is inherently more efficient.

Materials and recycling

What do we use?

At 3Dennis, we work primarily with PETG, a plastic that combines excellent properties with good recyclability. PETG is chemically related to PET, the material of drink bottles and one of the most recycled plastics in the world.

Our material scraps and failed prints don’t go to waste. We collect them separately by color and type, working with recycling partners who give this material a second life.

Bio-based alternatives

PLA, another popular 3D printing material, is made from renewable resources like corn starch. It’s biodegradable under industrial composting conditions. We use PLA for applications where mechanical properties suffice.

The nuance of bioplastics

Honesty requires saying that “biodegradable” doesn’t mean you can compost PLA in your backyard. It requires industrial composting with specific temperatures and conditions. In practice, much PLA still ends up in regular waste.

Still, the basis of renewable resources is a step forward compared to petroleum-based plastics.

Energy consumption in perspective

Critics rightly point to the energy consumption of 3D printers. A printer running for hours uses electricity. But how does this compare to alternatives?

Comparison with traditional production

An injection molding machine consumes significantly more energy per part when producing small runs. The machine must heat up, maintain temperature, and needs a lot of energy for the high pressure of the injection process.

CNC machines consume energy for the milling movement plus cooling plus chip extraction. For complex parts, this can take hours.

3D printers are relatively economical. A typical FDM printer consumes 100-300 Watts, comparable to a laptop or small household appliance.

Green power

At 3Dennis, our printers run on green power. This virtually eliminates the CO2 emissions of our production process. It’s a simple but effective measure any 3D printing operation can take.

Extending product life through repair

An often-forgotten environmental benefit of 3D printing is the ability to repair products instead of throwing them away.

Printing replacement parts

How many appliances end up in the garbage because one small plastic part broke? A clip, a hinge, a holder - parts that can no longer be ordered or whose manufacturer no longer exists.

With 3D printing, you simply make these parts again. We regularly help customers reverse-engineer and reproduce broken parts, saving complete appliances from the scrap heap.

Economical repair

Previously, repair was often more expensive than replacement. 3D printing changes that economy. A custom replacement part often costs only a few euros in material and an hour of print time.

This makes repair attractive again, with direct environmental benefits as a result.

Where we can still improve

We want to be honest: 3D printing isn’t perfect. There are areas where the technology and industry can still make strides.

Scaling material recycling

Although materials are technically recyclable, infrastructure for recycling 3D print waste is still underdeveloped. This is an industry-wide challenge we’re actively working on.

Greening energy sources

Not every 3D print service runs on green power. As an industry, we can collectively improve here.

Increasing awareness

Many designers don’t yet think in terms of 3D printability or repairability. Design for repair and design for recycling are concepts that need broader adoption.

Our contribution

At 3Dennis, we try to set a good example:

• Production on 100% green power
• Material scraps collected separately for recycling
• Local production and short supply lines
• Advice to customers on sustainable material choices
• Designs optimized for minimal material usage

Conclusion

3D printing isn’t a magic solution for all environmental problems, but it does offer concrete benefits: less material waste, local production, and possibilities for repair and recycling.

The technology develops rapidly, and with each generation of printers and materials, environmental benefits grow. We believe 3D printing is an important part of a more sustainable manufacturing industry.

Want to know how 3D printing can make your products more sustainable? Contact us for a conversation about the possibilities.