Material efficiency at the component level: how much metal can we do without?

Global production of steel and aluminium is a major driver of greenhouse gas emissions. Various processes might allow continued primary production of the two metals, but all depend on emissions-free electricity or carbon storage, and global capacity of these two key resources will be below demand for decades to come. As a result, zero-emissions steel and aluminium will mainly come from recycling, but supply will be lower than demand. This motivates demand reduction, and for the first time, this article estimates the inefficiency in current metal use by component type. The results demonstrate that around 80% of steel and 90% of aluminium liquid metal produced today may be unnecessary. Around 40% of liquid steel and 60% of liquid aluminium are never used in final components as they are removed along the supply chain of manufacturing. Of the metal that enters final service, approximately one-third could be saved by avoiding component over-specification. A further third could be saved, where the properties of metal are not used to their limits. These results point to specific opportunities for innovation in design and manufacturing technology, of which the highest priority is to re-think the use of sheet metal in construction.This article is part of the discussion meeting issue 'Sustainable metals: science and systems'.