Application of multi-criteria decision and simulation approaches to selection of additive manufacturing technology for aerospace application

Abstract

This study evaluates the Fuzzy Analytical Hierarchy Process (FAHP) as a multi-criteria decision (MCD) support tool for selecting appropriate additive manufacturing (AM) techniques that align with cleaner production and environmental sustainability. The FAHP model was validated using an example of the production of aircraft components (specifically fuselage) employing AM technologies such as Wire Arc Additive Manufacturing (WAAM), laser powder bed fusion (L-PBF), Binder Jetting (BJ), Selective Laser Sintering (SLS), and Laser Metal Deposition (LMD). The selection criteria prioritized eco-friendly manufacturing considerations, including the quality and properties of the final product (e.g., surface finish, high strength, and corrosion resistance), service and functional requirements, weight reduction for improved energy efficiency (lightweight structures), and environmental responsibility. Sustainability metrics, such as cost-effectiveness, material efficiency, waste minimization, and environmental impact, are central to the evaluation process. A computer-aided modeling approach was also used to simulate the performance of aluminum (AA7075 T6), steel (304), and titanium alloy (Ti6Al4V) for fuselage development. The results demonstrate that MCD approaches such as FAHP can effectively guide the selection of AM technologies that meet functional and technical requirements while minimizing environmental degradation footprints. Furthermore, the aluminum alloy outperformed the other materials investigated in the simulation with the lowest stress concentration and least deformation. This study contributes to advancing cleaner production practices by providing a decision-making framework for sustainable and eco-friendly manufacturing, enabling manufacturers to adopt AM technologies that promote environmental responsibility and sustainable development, while maintaining product quality and performance.