Additive manufacturing (AM) has emerged as an enabling technology for producing lightweight and geometrically complex components in aerospace applications. This study investigates alternative manufacturing routes for a critical servo bracket used in a Vertical Take-Off and Landing (VTOL) Unmanned Aerial Vehicle (UAV) platform, aiming to comparatively evaluate their environmental, economic, and operational performance within a life cycle perspective. The servo bracket was manufactured using CNC milling, Selective Laser Melting (SLM), and Metal Extrusion Additive Manufacturing (MEX/M) and the three routes were assessed using Life Cycle Assessment (LCA), Life Cycle Cost (LCC), and process-based indicators, including production time and production process. The results indicate that CNC milling exhibits the highest carbon footprint per part (156.3 kg CO2-eq.), mainly due to aluminium chip waste, whereas electricity consumption is the dominant contributor in SLM. Production times were 8.9 h for CNC, 52.7 h for SLM, and 71.6 h for MEX/M. From an economic perspective, CNC provides the lowest unit cost, while SLM is associated with the highest cost due to machine depreciation. Overall, the findings highlight distinct trade-offs between conventional and metal additive manufacturing routes and provide a life cycle-based decision framework for selecting suitable manufacturing strategies for VTOL UAV structural components.
Neslihan Top (Tue,) studied this question.