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)
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| Presentation Title |
Simulation-Aided Iterative Redesign for Laser Powder Bed Fusion Additive Manufacturing of a Complex Ti-6Al-4V Part |
| Author(s) |
Jonathan David Reyes Ortiz, Anthony D. Rollett, Sneha Prabha Narra |
| On-Site Speaker (Planned) |
Jonathan David Reyes Ortiz |
| Abstract Scope |
Laser powder bed fusion (LPBF) of geometrically complex parts requires rigorous Design for Additive Manufacturing (DfAM) strategies that preserve part functionality, critical features, and post-build characterization requirements. This work presents the simulation-aided iterative redesign for successful printing of an industry-relevant complex part, referred to as "Challenge Part," in Ti-6Al-4V on an EOS M290 system at Carnegie Mellon University. The part underwent five design iterations ranging from a minimal redesign with added fillets and tree supports to a hybrid strategy combining near self-supporting geometry using internal and external ribs to minimize distortion. Each iteration was evaluated by tracking thermal history, displacement, and von Mises equivalent stress in Autodesk Netfabb 2025, with selected cases cross-checked in the Ansys AM LPBF Thermal-Structural module. The final iteration significantly reduced the initially predicted distortion and stress values, and was successfully printed in approximately five days. |
| Proceedings Inclusion? |
Undecided |