Feature-based energy consumption quantitation strategy for complex additive manufacturing parts

Additive manufacturing (AM) has significant advantages, including design freedom, mass customization, and complex-structure manufacturing capabilities. As reducing the manufacturing energy is challenging in terms of the industrial sustainability, the AM energy consumption must be further explored. Existing energy consumption quantitation methods for AM require complex models that considering the energy characteristics of equipment. Therefore, we propose a feature-based energy consumption quantitation method for complex AM parts using simple models and suitable for different AM technologies. First, a feature segmentation method is proposed to divide complex AM parts into typical AM features. Then, the energy consumption model for each AMF is developed for energy consumption quantification during part fabrication. Finally, the energy consumption of a typical mechanical part manufactured via three different AM processes is investigated using the proposed method and measured experimentally. The results show that the proposed method can effectively and rapidly predict the energy consumption of AM processes with an accuracy of more than 95%. Furthermore, the efficiency of the three AM processes is compared and discussed to address suitable efficiency improvement methods. In general, the proposed method can be integrated into three-dimensional AM models, providing a reference for the structural optimization of AM parts and sustainable manufacturing.