Additive Manufacturing (AM) can improve material efficiency, reduce waste, and simplify assemblies via part consolidation, but its broader production and environmental impacts are nuanced. This study examines trade-offs in AM with part consolidation across production volumes using an eight-piece steel bracket as a case study. The analysis tests whether AM’s benefits persist at scale or whether thresholds exist where conventional manufacturing (CM) outperforms. Multiple consolidation scenarios are analyzed, balancing sustainability metrics with operational factors such as building time and post processing complexity. To capture real-world constraints, a decision-support framework is developed that incorporates commercially available material formats, geometric limitations, and process-specific losses. The framework is benchmarked against a common fixed Buy-to-Fly (BTF) ratio model, which can underestimate material waste and associated impacts. Using life-cycle assessment and multi-criteria decision analysis, the study estimates material use, energy consumption, emissions, cost, and production time.