| Abstract Scope |
In additive manufacturing (AM), stress drives distortion, warping, delamination, and cracking, making fast and accurate stress prediction essential for process planning, real-time control, digital twins, and data-driven workflows. However, spot-wise thermo-elasto-plastic FEM is often too slow for design iteration or real-time use, while existing semi-analytical approaches are mostly limited to 2D. This paper presents a full 3D semi-analytical thermo-elasto-plastic model for AM. A spot-wise analytical thermal solution is used as the load, and displacements and stresses are computed through Green’s function representations in a half-space. Plastic flow is integrated using an implicit return-mapping algorithm. A surface-consistent singular integral regularization ensures stable and accurate stress evaluation near the traction-free top surface. The model is validated against FEM, showing close agreement in temperature, displacement, and stress fields. Runtime comparisons show up to 1,670× speedup, enabling scalable data generation, scan optimization, and adaptive AM control. |