Laser specific energy consumption: How do laser systems compare to other manufacturing processes?

Laser material interactions are routinely praised for their selective processing and high processing rates. However, this does not guarantee that the total manufacturing system has a low energy intensity compared to conventional manufacturing processes. This paper presents the results of a collaborative UK and China research project to improve the comprehension of the total energy consumption and carbon emissions for laser-based manufacturing. A range of individual laser cutting, welding, and cleaning processes were studied to assess their energy efficiency, including the laser and its ancillary subsystems (e.g., cooling and extraction). The project developed a systematic analysis method, adapted from BS ISO 14955-1:2017, which incorporated time and subsystem level studies to quantify all energy consumption components of a laser system. Previous research has identified that the laser system's most significant contributor to the total energy consumption are the auxiliary or supporting subsystems, not the laser emission. This identified that using only the absorbed radiation to evaluate manufacturing efficiency is misleading. All the processes evaluated followed a negative correlation between processing rate (kg/h) and specific energy consumption (J/kg). The new data conclude that laser processes have a relatively high energy intensity compared to conventional manufacturing alternatives. The results can be used to identify where the most significant improvements to individual laser systems can be made. The comprehensive comparison of processes allows manufacturers to select processes to improve environmental impact.