Improving ESG Performance with Life Cycle Sustainability Assessment- Lessons from Additive Manufacturing

Additive manufacturing is increasingly promoted as a pathway toward sustainable production; however, its Environmental, Social, and Governance (ESG) implications remain insufficiently defined at the operational level. This study addresses this gap by developing a governance implications assessment framework to interpret empirically validated life cycle sustainability assessment (LCSA) evidence for post-consumer recycled polylactic acid (PC-PLA)-based fused filament fabrication (FFF) within the Australian manufacturing context. The central contribution lies in demonstrating how LCSA evidence can be translated into decision-relevant ESG information without reliance on product declaration frameworks or simplified circularity claims. While LCAs and EPDs do not directly optimise production systems, sustainability-oriented governance can guide engineering and operational decisions by managing whole-system trade-offs and future risk. The framework integrates mechanical validation, service-life-normalised LCSA results, circularity metrics, and material flow modelling through a consequences analysis lens. Results indicate that a V50:R50 (vPLA:PC-PLA) blend achieves balanced performance, delivering a 57% reduction in global warming potential while maintaining functional durability. However, these benefits are governance-contingent; managing an 11.7% increase in service-life-normalised costs requires senior-level oversight, formalised material traceability, and structured workforce training. Waste diversion analysis further demonstrates that scalability is constrained primarily by upstream collection and sorting efficiency rather than fabrication performance. The study concludes with a strategic roadmap advocating regional recycling hubs, certified micro-credentials, and adoption of decision-relevant governance metrics aligned with ASRS S1 and S2 disclosure standards. The proposed framework offers a transferable approach for translating engineering-level sustainability evidence into credible governance insights, strengthening accountability and supporting Australia’s transition toward resilient, circular manufacturing.