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<p>Sustainable manufacturing requires precise energy control, particularly in energy-intensive processes like laser powder bed fusion (PBF-LB/M), commonly known as selective laser melting. However, efforts to optimize efficiency are severely hindered by the legacy G-code standard (ISO6983). Due to its unidirectional nature, G-code is incapable of storing “as-manufactured” performance data, trapping valuable energy metrics in proprietary logs and preventing feedback-driven improvement. To overcome this disconnect across diverse manufacturing systems, a highly interoperable data framework is essential. This study addresses this gap by proposing a standardized extension to the STEP-NC (ISO 14649) data model to explicitly represent and store PBF-LB/M energy consumption (EC) data. New domain-specific EXPRESS entities were defined to capture process-level energy attributes, effectively transforming the NC file into a traceable record of environmental performance. Empirical case studies demonstrate the framework’s high fidelity, achieving a data translation error of less than 2% and demonstrating a predictive accuracy of 1.69% for new part designs. Furthermore, the model inherently supports multidimensional data querying, enabling users to pinpoint energy-intensive machine subsystems and printing stages accurately. By establishing a standardized infrastructure for data retention, this research provides the digital energy passport required for closed-loop, energy-aware process redesign.</p>

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Energy consumption model for laser powder bed fusion process based on STEP-NC data structure

  • 期刊论文

  • 发表日期：

    2026年7月10日

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  • Shao Wei Koh,
  • Aini Zuhra Abdul Kadir,
  • Kuan Yew Wong,
  • Kamran Latif,
  • Nurul Husna Mohd Yusoff,
  • Tao Peng

摘要

Sustainable manufacturing requires precise energy control, particularly in energy-intensive processes like laser powder bed fusion (PBF-LB/M), commonly known as selective laser melting. However, efforts to optimize efficiency are severely hindered by the legacy G-code standard (ISO6983). Due to its unidirectional nature, G-code is incapable of storing “as-manufactured” performance data, trapping valuable energy metrics in proprietary logs and preventing feedback-driven improvement. To overcome this disconnect across diverse manufacturing systems, a highly interoperable data framework is essential. This study addresses this gap by proposing a standardized extension to the STEP-NC (ISO 14649) data model to explicitly represent and store PBF-LB/M energy consumption (EC) data. New domain-specific EXPRESS entities were defined to capture process-level energy attributes, effectively transforming the NC file into a traceable record of environmental performance. Empirical case studies demonstrate the framework’s high fidelity, achieving a data translation error of less than 2% and demonstrating a predictive accuracy of 1.69% for new part designs. Furthermore, the model inherently supports multidimensional data querying, enabling users to pinpoint energy-intensive machine subsystems and printing stages accurately. By establishing a standardized infrastructure for data retention, this research provides the digital energy passport required for closed-loop, energy-aware process redesign.