This paper attempts to conduct a comparative life cycle environmental analysis of alternative versions of a product that was manufactured with the use of additive technologies. The aim of the paper was to compare the environmental assessment of an additive-manufactured product using two approaches: a traditional one, based on the use of SimaPro software, and the authors’ own concept of a newly developed artificial intelligence (AI) based approach. The structure of the product was identical and the research experiments consisted in changing the materials used in additive manufacturing (from polylactic acid (PLA) to acrylonitrile butadiene styrene (ABS)). The effects of these changes on the environmental factors were observed and a direct comparison of the effects in the different factors was made. SimaPro software with implemented databases was used for the analysis. Missing information on the environmental impact of additive manufacturing of PLA and ABS parts was taken from the literature for the purpose of the study. The novelty of the work lies in the results of a developing concurrent approach based on AI. The results showed that the artificial intelligence approach can be an effective way to analyze life cycle assessment (LCA) even in such complex cases as a 3D printed medical exoskeleton. This approach, which is becoming increasingly useful as the complexity of manufactured products increases, will be developed in future studies.

Reviewing the current state of knowledge on sustainable production, this paper opens the Special Section entitled “Sustainability in production in the context of Industry 4.0”. The fourth industrial revolution (Industry 4.0), which embodies a vision for the future system of manufacturing (production), focuses on how to use contemporary methods (i.e. computerization, robotization, automation, new business models, etc.) to integrate all manufacturing industry systems to achieve sustainability. The idea was introduced in 2011 by the German government to promote automation in manufacturing. This paper shows the state of the art in the application of modern methods in sustainable manufacturing in the context of Industry 4.0. The authors review the past and current state of knowledge in this regard and describe the known limitations, directions for further research, and industrial applications of the most promising ideas and technologies.

By reviewing the current state of the art, this paper opens a Special Section titled “The Internet of Things and AI-driven optimization in the Industry 4.0 paradigm”. The topics of this section are part of the broader issues of integration of IoT devices, cloud computing, big data analytics, and artificial intelligence to optimize industrial processes and increase efficiency. It also focuses on how to use modern methods (i.e. computerization, robotization, automation, machine learning, new business models, etc.) to integrate the entire manufacturing industry around current and future economic and social goals. The article presents the state of knowledge on the use of the Internet of Things and optimization based on artificial intelligence within the Industry 4.0 paradigm. The authors review the previous and current state of knowledge in this field and describe known opportunities, limitations, directions for further research, and industrial applications of the most promising ideas and technologies, considering technological, economic, and social opportunities.

The study aimed to develop a system supporting technological process planning for machining and 3D printing. Such a system should function similarly to the way human experts act in their fields of expertise and should be capable of gathering the necessary knowledge, analysing data, and drawing conclusions to solve problems. This could be done by utilising artificial intelligence (AI) methods available within such systems. The study proved the usefulness of AI methods and their significant effectiveness in supporting technological process planning. The purpose of this article is to show an intelligent system that includes knowledge, models, and procedures supporting the company’s employees as part of machining and 3D printing. Few works are combining these two types of processing. Nowadays, however, these two types of processing overlap each other into a common concept of hybrid processing. Therefore, in the opinion of the authors, such a comprehensive system is necessary. The system-embedded knowledge takes the form of neural networks, decision trees, and facts. The system is presented using the example of a real enterprise. The intelligent expert system is intended for process engineers who have not yet gathered sufficient experience in technological-process planning, or who have just begun their work in a given production enterprise and are not very familiar with its machinery and other means of production.

Artificial intelligence (AI) is changing many areas of technology in the public and private spheres, including the economy. This report reviews issues related to machine modelling and simulations concerning further development of mechanical devices and their control systems as part of novel projects under the Industry 4.0 paradigm. The challenges faced by the industry have generated novel technologies used in the construction of dynamic, intelligent, flexible and open applications, capable of working in real time environments. Thus, in an Industry 4.0 environment, the data generated by sensor networks requires AI/CI to apply close-to-real-time data analysis techniques. In this way industry can face both fresh opportunities and challenges, including predictive analysis using computer tools capable of detecting patterns in the data based on the same rules that can be used to formulate the prediction.

Computational intelligence (CI) can adopt/optimize important principles in the workflow of 3D printing. This article aims to examine to what extent the current possibilities for using CI in the development of 3D printing and reverse engineering are being used, and where there are still reserves in this area. Methodology: A literature review is followed by own research on CI-based solutions. Results: Two ANNs solving the most common problems are presented. Conclusions: CI can effectively support 3D printing and reverse engineering especially during the transition to Industry 4.0. Wider implementation of CI solutions can accelerate and integrate the development of innovative technologies based on 3D scanning, 3D printing, and reverse engineering. Analyzing data, gathering experience, and transforming it into knowledge can be done faster and more efficiently, but requires a conscious application and proper targeting.