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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…

Computational Engineering, Finance, and Science · Computer Science 2024-09-23 Jiarui Xie , Zhuo Yang , Chun-Chun Hu , Haw-Ching Yang , Yan Lu , Yaoyao Fiona Zhao

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,…

Systems and Control · Electrical Eng. & Systems 2025-01-22 Mikhail Khrenov , William Frieden Templeton , Sneha Prabha Narra

The mitigation of material defects from additive manufacturing (AM) processes is critical to reliability in their fabricated parts and is enabled by modeling the complex relations between available build monitoring signals and final…

Applied Physics · Physics 2024-02-26 Qixiang Luo , John D. Shimanek , Timothy W. Simpson , Allison M. Beese

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…

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…

Mathematical Physics · Physics 2025-11-11 Sebastian Basterrech , Shuo Shan , Debabrata Adhikari , Sankhya Mohanty

Transfer learning (TL) based additive manufacturing (AM) modeling is an emerging field to reuse the data from historical products and mitigate the data insufficiency in modeling new products. Although some trials have been conducted…

Machine Learning · Computer Science 2023-05-22 Yifan Tang , M. Rahmani Dehaghani , G. Gary Wang

Thermal multi-phase flow simulations are indispensable to understanding the multi-scale and multi-physics phenomena in metal additive manufacturing (AM) processes, yet accurate and robust predictions remain challenging. This book chapter…

Computational Engineering, Finance, and Science · Computer Science 2022-06-13 Jinhui Yan , Qiming Zhu , Ze Zhao

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…

Optimization and Control · Mathematics 2025-06-12 Yulin Guo , Boris Kramer

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…

Computational Engineering, Finance, and Science · Computer Science 2022-01-25 Sebastian L. Fuchs , Patrick M. Praegla , Christian J. Cyron , Wolfgang A. Wall , Christoph Meier

In metals additive manufacturing (AM), materials and components are concurrently made in a single process as layers of metal are fabricated on top of each other in the near-final topology required for the end-use product. Consequently, tens…

Applied Physics · Physics 2020-05-12 N. S. Johnson , P. S. Vulimiri , A. C. To , X. Zhang , C. A. Brice , B. B. Kappes , A. P. Stebner

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…

Systems and Control · Electrical Eng. & Systems 2020-01-09 Nathaniel Wood , David Hoelzle

Surface defects in Laser Powder Bed Fusion (LPBF) pose significant risks to the structural integrity of additively manufactured components. This paper introduces TransMatch, a novel framework that merges transfer learning and…

Computer Vision and Pattern Recognition · Computer Science 2025-09-03 Mohsen Asghari Ilani , Yaser Mike Banad

Additive Manufacturing (AM) is a manufacturing paradigm that builds three-dimensional objects from a computer-aided design model by successively adding material layer by layer. AM has become very popular in the past decade due to its…

Machine Learning · Computer Science 2019-08-12 Arindam Paul , Mojtaba Mozaffar , Zijiang Yang , Wei-keng Liao , Alok Choudhary , Jian Cao , Ankit Agrawal

Data-driven research in Additive Manufacturing (AM) has gained significant success in recent years. This has led to a plethora of scientific literature to emerge. The knowledge in these works consists of AM and Artificial Intelligence (AI)…

Information Retrieval · Computer Science 2024-07-29 Mutahar Safdar , Jiarui Xie , Andrei Mircea , Yaoyao Fiona Zhao

The recent explosion of machine learning (ML) and artificial intelligence (AI) shows great potential in the breakthrough of metal additive manufacturing (AM) process modeling. However, the success of conventional machine learning tools in…

Computational Engineering, Finance, and Science · Computer Science 2020-09-17 Qiming Zhu , Zeliang Liu , Jinhui Yan

Among metal additive manufacturing technologies, powder-bed fusion features very thin layers and rapid solidification rates, leading to long build jobs and a highly localized process. Many efforts are being devoted to accelerate simulation…

Computational Engineering, Finance, and Science · Computer Science 2020-06-26 Eric Neiva , Michele Chiumenti , Miguel Cervera , Emilio Salsi , Gabriele Piscopo , Santiago Badia , Alberto F. Martín , Zhuoer Chen , Caroline Lee , Christopher Davies

Achieving desired mechanical properties in additive manufacturing requires many experiments and a well-defined design framework becomes crucial in reducing trials and conserving resources. Here, we propose a methodology embracing the…

Machine Learning · Computer Science 2024-09-04 Mahsa Amiri , Zahra Zanjani Foumani , Penghui Cao , Lorenzo Valdevit , Ramin Bostanabad

The aim of this work is to propose a new paradigm that imparts intelligence to metal parts with the fusion of metal additive manufacturing and artificial intelligence (AI). Our digital metal part classifies the status with real time data…

Understanding the thermal behavior of additive manufacturing (AM) processes is crucial for enhancing the quality control and enabling customized process design. Most purely physics-based computational models suffer from intensive…

Machine Learning · Computer Science 2023-01-20 Shuheng Liao , Tianju Xue , Jihoon Jeong , Samantha Webster , Kornel Ehmann , Jian Cao

This paper presents the first comprehensive literature review of deep learning (DL) applications in additive manufacturing (AM). It addresses the need for a thorough analysis in this rapidly growing yet scattered field, aiming to bring…

Machine Learning · Computer Science 2024-12-25 Amirul Islam Saimon , Emmanuel Yangue , Xiaowei Yue , Zhenyu James Kong , Chenang Liu
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