## 1 Introduction  
Global warming remains one of the most pressing environmental challenges, driven largely by the rising concentration of greenhouse gases in the atmosphere. Among these, CO\({}_{2}\) emissions from fossil-based industrial activities, including material production, manufacturing, and transportation, are significant contributors. As a result, sustainability has become a global priority, particularly in the manufacturing sector, which is a major energy consumer and carbon dioxide emitter. This sector faces growing pressure to decarbonize while meeting increasing demands for advanced materials and technologies [1, 2, 3, 4]. Sustainable development, as conceptualized by the Brundtland Commission, is grounded in three interconnected dimensions: economic, social, and environmental [5]. These dimensions are assessed using specific metrics: economic impact through cost, social impact qualitatively, and environmental impact via measures such as energy consumption and carbon emissions [6, 7]. This framework aligns with the \"Three P\" model, People, Planet, and Profit (or Prosperity), and the triple bottom line approach, which considers these dimensions as distinct yet interdependent forms of capital. Economic capital represents financial value, natural capital refers to environmental resources, and human capital addresses societal well-being [8]. Additive Manufacturing (AM), particularly laser-based powder bed fusion of metals (PBF-LB/M), has emerged as a cornerstone of sustainable manufacturing. AM offers transformative potential by enabling efficient material utilization, reducing production waste, and supporting circular economy principles. These characteristics make AM an ideal solution for producing lightweight, high-performance components that align with sustainability goals [9; 10]. Aluminum plays a pivotal role in energy transitions and lightweighting applications, especially in transportation and aerospace. Known for its high strength-to-weight ratio, durability, and recyclability, aluminum is a key material for sustainability [11; 12]. Recycling aluminum requires only 5% of the energy needed for primary production, significantly lowering carbon emissions and energy consumption [13]. Its lightweight properties further enhance energy efficiency, resulting in reduced fuel consumption and emissions in automotive and aerospace applications. Beyond transportation, aluminum contributes to energy-efficient buildings, solar panels, and electric vehicles, solidifying its importance in advancing global efficiency and eco-friendly industries [14; 15; 16; 17]. Processing aluminum alloys via PBF-LB/M presents significant opportunities to minimize environmental impacts in sectors where weight reduction is critical, such as the automotive and aerospace sectors [9]. As a driving force of the Fourth Industrial Revolution, PBF-LB/M enables the production of complex mechanical and structural components. Its layer-by-layer fabrication process offers unparalleled design freedom, superior material optimization, and the ability to produce intricate geometries. Additionally, PBF-LB/M supports the development of multi-part assemblies, functionally graded materials, and advanced meta-materials, capabilities often beyond the reach of traditional manufacturing [18; 19; 20]. The technology rapid adoption across industries such as aerospace, automotive, healthcare, and consumer goods underscores its transformative potential. Although the PBF-LB/M improved material efficiency and other advantages, aluminum processing through this promising AM technology remains energy-intensive. The energy demands associated with metal powder production, spanning feedstock melting, atomization, powder collection, classification, and secure storage, are significant contributors to the environmental footprint of PBF-LB/M [8; 21; 22].