Svenja Ehmsen, Li Yi, Moritz Glatt, Barbara S. Linke, Jan C. Aurich

• The unit process life cycle inventory is a modeling approach to estimate the energy demand and resource requirements of a unit process. Thus, a model of the unit process life cycle inventory for a specific manufacturing process can be used for quantifying the environmental impacts of specific products manufactured by that process. Within the approach, reusable models are developed for specific manufacturing processes. In this paper, the development and validation of a unit process life cycle inventory model for high-speed laser directed energy deposition is presented. This additive manufacturing process offers great potential for the industry due to its fast process speed. However, high-speed laser directed energy deposition has a high energy consumption and resource demand. Assessing the energy demand for individual manufactured products is a time-intensive process that requires expert knowledge. Thus, the development of an adaptable unit process life cycle inventory model enables more convenient assessment and improvement of its energy and resource efficiencies for producing different products. For the development of the model, the subsystems of a high-speed laser directed energy deposition machine are analyzed separately, e. g. the laser generator, the trajectory system, the powder feeder, and the suction system. Afterward, the energy and material demand of these subsystems are described in mathematical models. Finally, the model is validated by comparing the energy demands of three demonstration parts, measured by experiments, and predicted by the model.