Cradle-To-Gate Environmental Impact Assessment of EDM Wire-Cut and Laser Cutting Processes

Abstract

Non-traditional machining (NTM) processes, such as EDM wire-cut and laser cutting, are widely used in manufacturing for their ability to machine complex geometries and hard-to-cut materials. Despite their operational advantages, the environmental implications of these processes remain insufficiently understood. This study develops a structured cradle-to-gate environmental assessment framework to enable a systematic and reproducible comparison between EDM wire-cut and laser cutting for the production of an identical wrench component from mild steel. The framework is organised into sequential stages, including process selection, functional unit and system boundary definition, inventory data collection, and impact modelling using GaBi software. Key impact categories considered include Climate Change, Metal Depletion, Human Toxicity (Cancer), Ionising Radiation, and Freshwater Eutrophication. Results indicate that EDM wire-cut environmental impacts are primarily driven by electricity consumption and wire usage, whereas laser cutting impacts are dominated by high power demand and assist-gas consumption. The study highlights critical process parameters affecting environmental performance and identifies opportunities for impact reduction through optimized machine settings and resource usage. The novelty of this work lies in the introduction of a structured LCA framework tailored specifically for non-traditional machining, providing clear comparative evidence to support more informed and sustainable process selection. These findings offer practical guidance for manufacturers aiming to reduce environmental footprints while maintaining production efficiency.