Paper Titles
Advanced FE Modeling for Predicting Component Properties in Additive Manufacturing
p.299
Measurement of Forces Generated during Robotized Additive Manufacturing Process Using Pellet Extruder
p.313
Anisotropy and Stress-State-Dependent Fracture in Additively Manufactured Metals
p.325
Effect of Preheating Temperature on the Optimal Processing Windows of Inconel 718 Processed by Laser Power Bed Fusion
p.333
Effects of Current Density during Electrically Assisted Friction Stir Additive Manufacturing Hole Repair of AA 7075 on a Conventional Machine
p.347
Comparison between 2D and 3D Thermal Finite Element Models of Directed Energy Deposition
p.359
Additive Manufacturing of Automotive Metal Multi-Material Shunt Resistor: Cost and Carbon Footprint Analysis
p.373
Resistance to Fracture of Additively Manufactured Aluminium Alloy AlSi10Mg under Plane Stress Conditions
p.383
Effect of CuCr1Zr Cross-Contamination Level on Work Hardening Characteristics of AlSi10Mg Additive Manufactured Material
p.391

Additive Manufacturing of Automotive Metal Multi-Material Shunt Resistor: Cost and Carbon Footprint Analysis

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Abstract:

Additive manufacturing (AM) transforms automotive production by enabling lightweight, complex components with reduced material waste. The present contribution investigates multi-material AM for automotive demonstrators combining copper-manganese-nickel and copper alloys, leveraging their complementary structural, thermal, and electrical properties. Such a component from the automotive sector is benchmarked against the respective conventionally manufactured part. Key performance indicators include structural weight, manufacturing cost via Activity-Based Costing, production time, energy consumption, and CO₂ emissions. Although this investigation compares AM laboratory/semi-industrial-scale and conventional industrial-scale implementations, the multi-material AM can deliver significant system-level benefits in energy efficiency and vehicle performance. These advantages are realized despite existing challenges related to interfacial bonding and process integration, and notwithstanding the associated increases in weight, cost and carbon footprint.

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Info:

Periodical:

Key Engineering Materials (Volume 1047)

Pages:

373-382

Online since:

April 2026

Authors:

Nikolaos D. Alexopoulos*, Vasileios Zeimpekis, Evangelos Vasileiou, Theodoros Souxes, Ilona Lazaridou, Leonard Alberty, Ismail Uensal, Georg Schlick

Keywords:

ABC Costing, Additive Manufacturing, Automotive Shunt Resistor, Carbon Footprint, Manganin-Copper Alloys, Metallic Multi-Material 3D Printing

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Creative Commons CC BY 4.0

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* - Corresponding Author

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