Life cycle assessment of modular molds in industrial casting lines
DOI:
https://doi.org/10.37636/recit.v9n3e472Keywords:
Life cycle assessment, Modular molds, Casting, Sustainability, OEEAbstract
The industrial manufacturing of permanent-mold castings depends directly on the availability, performance, and service life of the molds employed. In particular, modular molds—capable of geometric adaptation, component interchangeability, and scalability based on production requirements—represent a strategic alternative for expanding product portfolio versatility and ensuring operational continuity in casting lines. However, the geometric complexity of the mold cavity required to produce the castings creates specific challenges regarding design, wear, maintenance, and functionality throughout the mold's lifecycle. This study evaluates the complete lifecycle of modular permanent molds implemented in industrial casting lines, covering stages from design, manufacturing, and commissioning to continuous production, degradation, maintenance, refurbishment, and end-of-life. The methodology integrates Process Analytical Technology (PAT) tools to characterize thermal and mechanical conditions, standardized Methods-Time Measurement (MTM) to assess operational efficiency, mechanical testing and non-destructive testing (NDT) to analyze structural deterioration, and key performance indicators such as Overall Equipment Effectiveness (OEE) to determine the mold's contribution to the line's overall productivity. The analysis was conducted based on multiple representative production runs—considering various modular configurations, thermal cycles, and maintenance scenarios—thereby enabling an assessment of the molding system's behavior under actual industrial operating conditions. The results demonstrate OEE ranges associated with optimized modular configurations, as well as a significant reduction in cumulative system costs compared to conventional permanent molds; this is primarily attributed to reduced downtime, a decrease in the total number of molds required, and the selective replacement of critical modules. Furthermore, an effective extension of the molding system's service life was observed, as the approach allows for partial mold refurbishment rather than complete replacement. The adopted approach distinguishes between Life Cycle Assessment (LCA)—geared toward quantifying environmental impacts associated with material and energy use and waste generation—and lifecycle engineering, which focuses on technical and operational decision-making during the mold's design, operation, and maintenance stages. Integrating both approaches enabled the creation of a robust analysis framework to optimize the technical, economic, and environmental performance of modular permanent molds in industrial casting lines.
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Copyright (c) 2026 Martha Angélica Cano-Figueroa, Hugo Arcos-Gutiérrez, Edgar Yered Boche-Cano, Víctor Hugo Mercado-Lemus, José Antonio Betancourt-Cantera
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