CAD-platform-based Process optimization Design Method by Selective Laser Melting Simulation

Additive Manufacturing based on Powder Bed Fusion processes enables the construction of end-use functional metal components, making it feasible to design several level of geometrical complexity. Nevertheless, the printing process leads to material and shape defects, residual stress and induced distortions on final components that mainly are caused by the high thermal gradients associated to the intense and nonuniform power energy sources used to selectively melt metal powders. In this paper, techniques to reduce or prevent these effects are summarized. The more broadly Design for Additive Manufacturing approach based on the use on CAD platforms for product-process design is the backbone upon this research is based on. Specifically, the work presents a design method to predict drawbacks and improve the industrialization subphase. Laser-based Powder Bed Fusion technique is considered and the implementation and validation of the Selective Laser Melting process simulation is performed in order to support the method. Two case studies are presented. The former demonstrates the simulation implementation feasibility through a CAD platform. The latter validates the simulation results compared to experimental data for further method application.