A scoping review of foundry technologies: environmental performance, regulatory context, and life cycle assessment perspectives

The 21st-century foundry industry is experiencing a profound transformation, driven by the interplay of regulatory, technological, and market-driven forces [1]. The objective of this scoping review is to map the current landscape of ferrous and non-ferrous casting technologies, identify production practices, evaluate environmental performance frameworks, and assess the maturity and readiness of emerging processes. The study synthesises information from peer-reviewed literature, grey literature, and technical standards. It analyses foundry industry technologies encompassing the full spectrum of TRL levels: from commercially mature processes (TRL 9), such as sand casting and permanent mould casting, to emerging technologies at TRL levels 6-9, including 3D-printed moulds, alternative binders, and applications of life cycle assessment. The review is based on a systematically screened body of sources, including peer-reviewed journal articles and international standards. The literature search identified 3,501 records, of which 583 studies met the predefined eligibility criteria and were included in the final evidence synthesis. In cases where peer-reviewed data are limited or unavailable, selected industry publications and technical reports containing commercial data are incorporated based on predefined inclusion criteria and credibility assessment procedures, and their findings are cross-checked against available scientific and regulatory sources. Such sources are employed primarily to characterise technological maturity, industrial deployment, and practical performance trends rather than to establish definitive environmental benchmarks. The environmental analysis is informed by LCA-based evidence; however, the study does not provide a harmonised comparative LCA or a quantitative meta-analysis across technologies.