About this Abstract |
| Meeting |
2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
|
| Symposium
|
2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
|
| Presentation Title |
First-Time-Right Smart Additive Manufacturing – A Physics-Based Feedforward Control Approach for Design and Process Optimization in Laser Powder Bed Fusion |
| Author(s) |
Christopher Williams, David Spadaccia, Mihir Darji, Kaustubh Deshmukh, Swayam Kudale, Prahalada K. Rao |
| On-Site Speaker (Planned) |
Prahalada K. Rao |
| Abstract Scope |
Two challenges hinder the industrial-scale production of LPBF components. First, a cumbersome and expensive trial-and-error testing approach is currently the norm for optimizing the build conditions for a LPBF component, such as placement of supports and determining the processing parameter window. Second, despite considerable process optimization, the process tends to drift leading to defect formation and build failures. To overcome these challenges, the objective of this work was to develop and implement a physics-based feedforward control strategy to optimize support placement and processing parameters. The approach consists of two steps. First, a rapid thermal model is used to understand and predict the effect of various support placement strategies on heat buildup. Second, a feedforward model predictive control strategy is devised to modulate the laser power and velocity layer-by-layer so as to avoid deleterious temperature excursions. The approach eliminated part defects and reduces necessary support structure weight by 45%. |
| Proceedings Inclusion? |
Planned: Post-meeting proceedings |