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Process optimization for metal additive manufacturing (AM) is crucial to ensure repeatability, control microstructure, and minimize defects. Despite efforts to address this via the traditional design of experiments and statistical process…
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…
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…
In recent years, the demand for customized, on-demand production has grown in the manufacturing sector. Additive Manufacturing (AM) has emerged as a promising technology to enhance customization capabilities, enabling greater flexibility,…
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…
An additive manufacturing (AM) process, like laser powder bed fusion, allows for the fabrication of objects by spreading and melting powder in layers until a freeform part shape is created. In order to improve the properties of the material…
We introduce a method to analyze and modify a shape to make it manufacturable for a given additive manufacturing (AM) process. Different AM technologies, process parameters or materials introduce geometric constraints on what is…
Microstructure evolution in metal additive manufacturing (AM) is a complex multi-physics and multi-scale problem. Understanding the impact of AM process conditions on the microstructure evolution and the resulting mechanical properties of…
The central security issue of outsourced 3D printing (aka AM: Additive Manufacturing), an industry that is expected to dominate manufacturing, is the protection of the digital design (containing the designers' model, which is their…
Hybrid manufacturing (HM) technologies combine additive and subtractive manufacturing (AM/SM) capabilities in multi-modal process plans that leverage the strengths of each. Despite the growing interest in HM technologies, software tools for…
We present an efficient approach to quantify the uncertainties associated with the numerical simulations of the laser-based powder bed fusion of metals processes. Our study focuses on a thermomechanical model of an Inconel 625 cantilever…
The bottleneck of alloy design for powder-based additive manufacturing (AM) resides in customized powder production - an expensive and time-consuming process hindering the rapid closed-loop design iterations. This study analyzed an…
Designing the microstructure of Fe-Ni permalloy by additive manufacturing (AM) opens new avenues to tailor the materials' magnetic properties. Yet, AM-produced parts suffer from spatially inhomogeneous thermal-mechanical and magnetic…
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…
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…
Metal additive manufacturing (AM) processes often fabricate a near-net shape that includes the as-designed part as well as the sacrificial support structures that need to be machined away by subtractive manufacturing (SM), for instance…
Laser Additive Manufacturing (LAM) presents unparalleled opportunities for fabricating complex, high-performance structures and components with unique material properties. Despite these advancements, achieving consistent part quality and…
Accurately predicting the temperature field in metal additive manufacturing (AM) processes is critical to preventing overheating, adjusting process parameters, and ensuring process stability. While physics-based computational models offer…
Adhesive joints are increasingly used in industry for a wide variety of applications because of their favorable characteristics such as high strength-to-weight ratio, design flexibility, limited stress concentrations, planar force transfer,…
Inverse design problems are common in engineering and materials science. The forward direction, i.e., computing output quantities from design parameters, typically requires running a numerical simulation, such as a FEM, as an intermediate…