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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…
Additive manufacturing (AM) processes produce parts with improved physical, chemical, and mechanical properties compared to conventional manufacturing processes. In AM processes, intricate part geometries are produced from multicomponent…
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)…
The promise of Additive Manufacturing (AM) includes reduced transportation and warehousing costs, reduction of source material waste, and reduced environmental impact. AM is extremely useful for making prototypes and has demonstrated 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…
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…
Additive friction stir deposition (AFSD) is a novel solid-state additive manufacturing technique that circumvents issues of porosity, cracking, and properties anisotropy that plague traditional powder bed fusion and directed energy…
Fusion-based metal additive manufacturing (AM) is a disruptive technology that can be employed to fabricate metallic component of near-net-shape with an unprecedented combination of superior properties. However, the interrelationship…
Additive manufacturing (AM) technology is undergoing rapid development and emerging as an advanced technique that can fabricate complex near-net shaped and light-weight metallic parts with acceptable strength and fatigue performance. A…
Model-based process simulation can be used to derive designs and operating conditions of chemical processes that optimally balance multiple objectives, such as quality, costs, or environmental impacts. This work focuses on identifying…
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…
Additive manufacturing (AM) of metallic components promises many advantages over conventional manufacturing processes through high design flexibility across multiple length scales and precision coupled with an astonishing combination of…
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…
A support structure is required to successfully create structural parts in the powder bed fusion process for additive manufacturing. In this study, we present the topology optimization of a support structure that improves the heat…
Informing Additive Manufacturing (AM) technology adoption decisions, this paper investigates the relationship between build volume capacity utilisation and efficient technology operation in an inter-process comparison of the costs of…
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,…
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…
Topology optimization produces designs with intricate geometries and complex topologies that require advanced manufacturing techniques such as additive manufacturing (AM). However, insufficient consideration of manufacturability during the…
We present a novel computational paradigm for process design in manufacturing processes that incorporates simulation responses to optimize manufacturing process parameters in high-dimensional temporal and spatial design spaces. We developed…
Additive Manufacturing (AM) is a powerful technology that produces complex 3D geometries using various materials in a layer-by-layer fashion. However, quality assurance is the main challenge in AM industry due to the possible time-varying…