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Powder Bed Fusion (PBF) is a type of Additive Manufacturing (AM) technology that builds parts in a layer-by-layer fashion out of a bed of metal powder via the selective melting action of a laser or electron beam heat source. The technology…

This article proposes a novel high-performance computing approach for the prediction of the temperature field in powder bed fusion (PBF) additive manufacturing processes. In contrast to many existing approaches to part-scale simulations,…

Powder bed fusion is a widely used additive manufacturing (AM) process for producing complex, small-batch parts that are impractical to manufacture using conventional methods. However, its broader adoption is hindered by process-induced…

Additive manufacturing (AM) techniques hold promise but face significant challenges in process planning and optimization. The large temporal and spatial variations in temperature that can occur in layer-wise AM lead to thermal excursions,…

Metal Laser Powder Bed Fusion (PBF-LB/M) is a leading additive manufacturing technique in which part quality and grain morphology are highly dependent on process parameters. Numerous studies of process variations, such as laser power, scan…

Powder Bed Fusion (PBF) is an important Additive Manufacturing (AM) process that is seeing widespread utilization. However, due to inherent process variability, it is still very costly and time consuming to certify the process and the part.…

In this study, we leverage a mixture model learning approach to identify defects in laser-based Additive Manufacturing (AM) processes. By incorporating physics based principles, we also ensure that the model is sensitive to meaningful…

Laser powder bed fusion (L-PBF) of semi-crystalline polymers such as polyamide-12 (PA12) has found increasing use in various industrial applications. However, achieving high dimensional accuracy remains a significant challenge. Despite the…

Foundation models are at the forefront of an increasing number of critical applications. In regards to technologies such as additive manufacturing (AM), these models have the potential to dramatically accelerate process optimization and, in…

Metal additive manufacturing enables unprecedented design freedom and the production of customized, complex components. However, the rapid melting and solidification dynamics inherent to metal AM processes generate heterogeneous,…

Numerical simulations of a complete laser powder bed fusion (LPBF) additive manufacturing (AM) process are extremely challenging or even impossible to achieve without a radical model reduction of the complex physical phenomena occurring…

Laser Powder Bed Fusion (L-PBF) is a widely adopted additive manufacturing process for fabricating complex metallic parts layer by layer. Effective thermal management is essential to ensure part quality and structural integrity, as thermal…

Efficient simulation of Laser Powder Bed Fusion (LPBF) is crucial for process prediction due to the lasting issue of high computational cost associated with traditional numerical methods such as finite element analysis (FEA). While a…

Metal additive manufacturing via laser-based powder bed fusion (PBF-LB/M) faces performance-critical challenges due to complex melt pool and vapor dynamics, often oversimplified by computational models that neglect crucial aspects, such as…

Many additive manufacturing (AM) technologies rely on powder feedstock, which is fused to form the final part either by melting or by chemical binding with subsequent sintering. In both cases, process stability and resulting part quality…

Powder bed fusion (PBF) is an emerging metal additive manufacturing (AM) technology that enables rapid fabrication of complex geometries. However, defects such as pores and balling may occur and lead to structural unconformities, thus…

Laser powder bed fusion (L-PBF) is a widely recognized additive manufacturing technology for producing intricate metal components with exceptional accuracy. A key challenge in L-PBF is the formation of complex microstructures affecting…

Laser Powder Bed Fusion (LPBF) additive manufacturing has revolutionized industries with its capability to create intricate and customized components. The LPBF process uses moving heat sources to melt and solidify metal powders. The fast…

This work proposes an extension of phase change and latent heat models for the simulation of metal powder bed fusion additive manufacturing processes on the macroscale and compares different models with respect to accuracy and numerical…

Metal additive manufacturing (AM) by laser powder bed fusion (L-PBF) builds upon fundamentals established in the field of laser welding which include the influence of gas and plume dynamics on weld depth and quality. L-PBF demands a…