Avaliação de ciclo de vida de postiços para moldes de baixo volume:análise comparativa entre processos de fabricação

Abstract

The manufacturing of inserts for low-volume molds still faces significant challenges related to high production costs, long lead times, and dependence on imported components, especially in tooling industries and sectors linked to agricultural parts production. In this context, it becomes necessary to evaluate alternative manufacturing routes that are not only technically feasible but also present improved environmental performance. However, there is still a gap in comparative studies that assess, from a Life Cycle Assessment (LCA) perspective, different materials and processes applied to the production of such inserts. Therefore, this study aimed to perform a comparative LCA between two manufacturing processes for low-volume mold inserts: machining of 5xxx series aluminum, characterized by high purity, thermal conductivity, and recyclability, and deposition using RG3280 resin. The analysis was conducted using a gate-to-gate approach, covering the shaping and machining stages of the final insert. The functional unit adopted was the production of one finished insert ready for installation. The modeling was carried out using SimaPro software, applying the IMPACT World+ method at the midpoint perspective. Primary data included energy consumption, machining time, material removal rate, and waste generation, while secondary data were obtained from databases and scientific literature. The results indicated that aluminum presents higher impacts in categories related to energy consumption and mineral resource extraction, whereas RG3280 resin showed disadvantages mainly due to its reliance on fossil resources and emissions associated with petrochemical synthesis. It is concluded that the selection of the manufacturing process depends on the prioritized environmental criteria, with resin being more favorable in several scenarios and potentially advantageous under conditions of lower energy intensity.