About this Abstract |
| Meeting |
2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
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| Symposium
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2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
|
| Presentation Title |
Reducing porosity and distortion through coupled multi-scale control of laser powder bed fusion |
| Author(s) |
Nicholas Kirschbaum, Chinedum Okwudire |
| On-Site Speaker (Planned) |
Nicholas Kirschbaum |
| Abstract Scope |
Achieving effective closed-loop process control remains a key challenge in LPBF. Previous work has separately explored scan-vector-level modulation of laser power to control the meltpool area and layer-wise scan sequencing to reduce residual stress and distortion. However, these methods are typically used independently, and limited work has examined how scan sequencing affects porosity. In prior work, we introduced a feedforward power-to-meltpool-area controller using a lightweight thermal model coupled with an analytical meltpool model. This work integrates an improved version of that controller with SmartScan, a layer-wise scan-sequencing algorithm developed at the University of Michigan that minimizes distortion by reordering scan vectors within each layer. Initial testing showed significant increases in porosity when using SmartScan alone, but porosity decreased when coupled with power control, without a significant increase in distortion. This multi-scale control framework reduces distortion while minimizing meltpool variability through feedforward vector-level control. |
| Proceedings Inclusion? |
Undecided |