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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…
Metal additive manufacturing (AM) opens the possibility for spatial control of as-fabricated microstructure and properties. However, since the solid state diffusional transformations that drive microstructure outcomes are governed by…
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…
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…
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…
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…
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 manufacturing (AM) enables enormous freedom for design of complex structures. However, the process-dependent limitations that result in discrepancies between as-designed and as-manufactured shapes are not fully understood. The…
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.…
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,…
Additive manufacturing (AM) enables the development of high-performance architected cellular materials, emphasizing the growing importance of establishing programmable and predictable energy absorption capabilities. This study evaluates the…
Additive manufacturing is a free-form manufacturing technique in which parts are built in a layer-by-layer manner. Laser powder bed fusion is one of the popular techniques used to fabricate metal parts. However, it induces residual stress…
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…
Open-loop control of laser powder bed fusion (LPBF) additive manufacturing (AM) has enabled the production of complex, high-criticality parts for various industries. This method relies on static parameter sets from extensive experimentation…
A topology optimization formulation including a model of the layer-by-layer additive manufacturing (AM) process is considered. Defined as a multi-objective minimization problem, the formulation accounts for the performance and cost of both…
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…
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…
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,…
Integrating topology optimization and additive manufacturing (AM) technology can facilitate innovative product development. However, laser powder bed fusion, which is the predominant method in metal AM, can lead to issues such as residual…
This paper investigates in hatching process strategies for additive manufacturing using an electron beam by numerical simulations. The underlying physical model and the corresponding three dimensional thermal free surface lattice Boltzmann…