Predictive defect model for highly productive laser powder bed fusion additive manufacturing

Abstract

This disclosure is directed to a method for modeling additive manufacturing of a part, including a number of steps. The steps include constructing a model for estimating output of a simulated additive manufacturing process, followed by entering process operating parameters for an additive manufacturing system into the model to produce an output. The output is compared to acceptance criteria to determine whether the output is acceptable or unacceptable. Next regions of operating parameters that support production of the part with acceptable quality characteristics are determined based upon the output. Regions of operating parameters that support production of the part with acceptable quality characteristics are added to a process map for additive manufacturing the part. The steps are repeated for different operating parameters until the process map is complete.