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Laser powder bed fusion (LPBF) holds promise to efficiently produce metal parts. However, LPBF incurs stochastic melt pool (MP) spattering, which would roughen workpiece in-process surface, thus weakening inter-layer bonding and causing…

Systems and Control · Electrical Eng. & Systems 2023-03-02 Haolin Zhang , Chaitanya Krishna Prasad Vallabh , Xiayun Zhao

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…

Numerical Analysis · Mathematics 2021-12-20 Massimo Carraturo , Alex Viguerie , Alessandro Reali , Ferdinando Auricchio

Additive manufacturing technologies enable the production of complex and bioinspired shapes using magneto-responsive materials, which find diverse applications in soft robotics. Particularly, the development of composites with controlled…

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…

Computational Engineering, Finance, and Science · Computer Science 2025-06-30 Augustine Twumasi , Prokash Chandra Roy , Zixun Li , Soumya Shouvik Bhattacharjee , Zhengtao Gan

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…

Systems and Control · Electrical Eng. & Systems 2025-09-22 Yukta Pareek , Abdul Malik Al Mardhouf Al Saadi , Amrita Basak , Satadru Dey

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…

Computational Engineering, Finance, and Science · Computer Science 2025-07-03 Magdalena Schreter-Fleischhacker , Nils Much , Peter Munch , Martin Kronbichler , Wolfgang A. Wall , Christoph Meier

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

Additive manufacturing by laser powder bed fusion (LPBF) offers material versatility, capability for complex geometries, and control of mechanical properties and microstructure. However, achieving high-quality output requires process…

Materials Science · Physics 2021-11-04 Suh In Kim , A. John Hart

This work investigated the effects of aging heat treatments on the microstructure and, consequently, the quasi-static (tensile properties) and dynamic (impact toughness) mechanical behaviour of a 17-4 PH stainless steel produced by powder…

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

Pore formation during Laser Powder Bed Fusion (LPBF) has long posed challenges in metal 3D printing, significantly affecting the mechanical properties of the final product. Porosity frequently occurs because of an unstable keyhole…

Computational Engineering, Finance, and Science · Computer Science 2024-10-29 Chuxiao Meng , Conor Porter , Sina Malakpour , Garrett Mathesen , Seongyeon Yang

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…

Medical Physics · Physics 2025-12-23 Zhongfeng Xu , Wei Zhu , Lionel Freire , Noëlle Billon , Jean-Luc Bouvard , Yancheng Zhang

We present a computational framework for the simulations of powder-bed fusion of metallic alloys, which combines: (1) CalPhaD calculations of temperature-dependent alloy properties and phase diagrams, (2) macroscale finite element (FE)…

Materials Science · Physics 2022-05-10 S. M. Elahi , R. Tavakoli , A. K. Boukellal , T. Isensee , I. Romero , D. Tourret

The microstructure of Ti-6Al-4V has a decisive impact on its mechanical performance; however, controlling phase composition during Laser Powder Bed Fusion (LPBF) remains difficult because of the inherent localized and cyclic thermal…

Computational Physics · Physics 2026-04-28 Carina van der Linde , Iason Sideris , Léa Deillon , Mohamadreza Afrasiabi , Markus Bambach

The stochastic formation of defects during Laser Powder Bed Fusion (L-PBF) negatively impacts its adoption for high-precision use cases. Optical monitoring techniques can be used to identify defects based on layer-wise imaging, but these…

Image and Video Processing · Electrical Eng. & Systems 2024-09-23 Francis Ogoke , Sumesh Kalambettu Suresh , Jesse Adamczyk , Dan Bolintineanu , Anthony Garland , Michael Heiden , Amir Barati Farimani

Laser powder bed fusion (LPBF) is an additive manufacturing technique that has gained popularity thanks to its ability to produce geometrically complex, fully dense metal parts. However, these parts are prone to internal defects and…

Computational Engineering, Finance, and Science · Computer Science 2025-07-18 Nicholas Kirschbaum , Nathaniel Wood , Chang-Eun Kim , Thejaswi U. Tumkur , Chinedum Okwudire

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,…

Computational Engineering, Finance, and Science · Computer Science 2023-09-18 Sebastian D. Proell , Peter Munch , Martin Kronbichler , Wolfgang A. Wall , Christoph Meier

Powder bed additive manufacturing processes such as laser powder bed fusion (LPBF) or binder jetting (BJ) benefit from using fine (D50 $\leq20~\mu m$) powders. However, the increasing level of cohesion with decreasing particle size makes…

Applied Physics · Physics 2025-04-29 Reimar Weissbach , Garrett Adams , Patrick M. Praegla , Christoph Meier , A. John Hart

Powder bed fusion additive manufacturing (PBFAM) of metals has the potential to enable new paradigms of product design, manufacturing and supply chains while accelerating the realization of new technologies in the medical, aerospace, and…

In this paper, we present the results of single-track experiments conducted for different fractions of standard AlSi10Mg powder, which were sieved to achieve varying mean size of the particles. We observed strong differences in the melting…

Other Condensed Matter · Physics 2025-08-01 Y. Solyaev , V. Dobryanskiy , Nguyen Long , Stanislav Chernyshikhin