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Meeting 2024 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2024)
Symposium 2024 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2024)
Presentation Title Toward Rapid Process Qualification of Laser Powder Bed Fusion Additive Manufacturing Using Physics-Based Model Predictive Control
Author(s) Prahalada K. Rao, Alex Riensche, Benjamin Bevans, Antonio Carrington, Kaustubh Deshmukh, Kamden Shephard, John Sions, Kyle Snyder, Yuri Plotnikov, Kevin Cole
On-Site Speaker (Planned) Prahalada K. Rao
Abstract Scope  We developed and applied a physics-guided model predictive control approach to autonomously optimize the processing parameters for an LPBF part before it is printed. The control approach creates a customized layer-by-layer processing plan for each LPBF part shape, such that the model-predicted thermal history of a part matches a predetermined ideal or target thermal history. Currently, LPBF processing parameters are optimized through empirical studies based on simple test coupons. However, processing parameters optimized for test coupons seldom transfer to practical parts necessitating further testing. We demonstrate, with relatively complex stainless steel 316L parts processed on a commercial EOS M290 LPBF machine, the following advantageous outcomes from using the physics-based model predictive control approach: (i) elimination of anchoring supports in parts with prominent overhang features; (ii) improvement in geometric accuracy and surface integrity of hard to access internal features; and (iii) reduction in microstructure heterogeneity resulting in consistent part properties.
Proceedings Inclusion? Definite: Post-meeting proceedings

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Mitigating Overspray in Aerosol Jet Printing: A Deep Learning Approach for Process Optimization
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Model Based Control of Fused Powder 3D Printing
Modeling of Laser Stirring Scan Strategy in LPBF for High-Throughput Applications
Modeling the Effect of Thermal Contact Resistance on Mechanical Properties in Fused Filament Fabrication
Mold Design using Binder-Jetted Sand for Aluminum Casting
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On the Effectiveness of PBF-LB Particle Dampers with Thin and Flat Cavities Considering Industrial Process Variances
On the Nature of Recoater Damage Powder Spreading Mechanics
On the use of Event-based Change Detection Neuromorphic Imagers for In-Process Monitoring of Additive Manufacturing
Ontology-based Retrieval Augmented Generation (RAG) for GenAI-Supported Additive Manufacturing
Optical Expansion of Projection-based 3D Printing
Optical Tomography based on Near Infrared Imaging for Spatter and Distortion Detection in LPBF
Optimal Silane Concentration for Strengthening PA12 and SFO Composite Filaments in FDM Printing: Preliminary Insights
Optimization of SiC Colloidal Ink for Direct-Write Additive Manufacturing via Dual-Polyelectrolyte Ratio Method
Optimizing Molten Metal Deposition (MMD) for Aluminum Alloys: A Synergetic Approach of Finite Element and Experimental Study
Overcoming the Resolution-Deposition Limit of Additive Manufacturing with Droplet-on-Demand Molten Metal Jetting
Overview of Key Technoeconomic Performance Metrics for Large-Format Directed Energy Deposition Metal Additive Manufacturing
Parametric Investigation of Single-Layer Stainless Steel 316L with Novel Laser Powder Bed Fusion Technology: Diode Area Melting with 450 nm Blue Lasers
Part-Level Heat Buildup Across Directed Energy Deposition Additive Manufacturing Processes
Part Deformation Constrained Multi-load Support Optimization for Laser Powder Bed Fusion
Passive Intensity Modulation Of Light In A Microscale Selective Laser Sintering System For Enhanced Part Uniformity
Performance Analysis of Selective Separation Shaping (SSS) Large-Scale Powder Bonding Technology
Phase-field Simulations of Solute Element Segregations at Various Interfaces in Additively Manufactured IN718 Ni-based Superalloy
Photocurable SLA Resin Formulation for Reduced Thermal Expansion
Physics-based Machine Learning for In-Situ Infrared Detection of Micropores in LPBF
Physics-based Modeling of Polymer-Metal Composites in Fused Filament Fabrication
PLA-HA/BBG Composite Scaffolds Fabricated by Digital Light Processing 3D Printing for Cranial Bone RegenerationRegeneration
Planar and Non-planar Print Patterns in PEEK Flat Backup Rings to Increase Seal Performance Under High Pressure and Temperature
Powder Feed Mechanism for Convection of High-Cohesion, Sub-20-Micron Powders in Directed Energy Deposition
Powder Packing and Part Removal in Compressed Powder Beds
PowderJet: An Agile System for High Quality Metal Powder Production
Pre-training Vision Encoders with Thermal Images for In-situ Process Monitoring in Laser Powder Bed Fusion
Predictability of Drag force Towards Optimizing Fingers to Aid Automation in the Depowdering Stage of Binder Jet AM & Granular Physics
Predicting Melt Pool Thermal Distribution in Ti-6Al-4V Directed Energy Deposition Using Machine Learning
Predicting Microstructure Properties Using Transfer Learning
Predicting Print Morphology in Aerosol Jet Printing Using Deep Learning-based cGANs
Predicting Recoater Interference in Laser Powder Bed Fusion Process by Considering Both Global Thermal Deformation and Local Edge Deformation
Predicting Surface Roughness in Laser Powder Bed Fusion Parts after Laser Polishing: A Multi-Physics Simulation Approach
Predicting the Fatigue Life of a Multi-Jet Fusion Fabricated Polyamide 11 Ankle-foot Orthosis: Durability Insights from S-N Curve Analysis
Prediction of Fatigue Properties of Fiber-reinforced Composites Manufactured by Material Extrusion
Predictive Modeling of Clay Drying Process in Ceramic 3D Printing
Prewetting of Binder Jet Print Beds to Improve Line Quality and Expand Print Windows
Probing the Effect of Dislocation Cell on the Plasticity and Anisotropy of Additively Manufactured Copper via Crystal Plasticity Finite Element Modeling
Probing the Process Window Boundaries in Powder Bed Fusion-Laser Beam of Ti-6Al-4V
Process Development and Control for Sensor-informed Hybrid-Additive Manufacturing
Process Limitation for Powder Bed Fusion with Laser Beam Multiplication
Process Optimization of Diode Point Melting Using Ti6Al4V in Laser Powder Bed Fusion
Process Parameter Development for SS316L on the Freemelt-ONE Open Architecture Electron Beam Powder Bed Fusion Machine
Process Parameter Effects on the Mechanical Behavior and Microstructure of Fused Filament Fabricated 17-4 PH
Process Planning Toolbox for Cold Spray Additive Manufacturing Iterative Build Plan Optimization
Processing Aluminum Alloys with Piezoelectric Driven Molten Metal Jetting
Processing of Recycled PEKK-CF in Powder Bed Fusion
Proposal for How to Treat L-PBF Like Any Other Plant: State Feedback Control Design and Computational Issues
Pros and Cons of Industrial Robotics in Additive Manufacturing
Prospects of Fusion Additively Manufactured Microstructures for Enhancing Hydrogen Embrittlement Resistance
Quantification of Recoating Forces in Binder Jetting
Quantitative Analysis of In-situ Pore Removal in Porous L-PBF Substrates
Rapid 3D Printing of Electro-Active Hydrogels
Rapid Curing of Ceramic Binder Mixtures Using Microwave Radiation
Rapid Screening of Liquid Metal Wetting for a Materials Compatibility Library
Re-Defining Catheter Care with Multi-Material Additive Manufacturing
Re-Imagining Additive Manufacturing through Multi-Material Laser Powder Bed Fusion
Real-Time Process Visualization in Thermoplastic Extrusion with Augmented Reality Monitoring
Reconfigurable Lattice of Auxetic Backlash Structures for Shape-Changing Surfaces
Reduction of Aging Mechanisms in a Polyamide 66 Material for Use in the Laser-based Powder Bed Fusion Process
Region of Interest Analysis for Top Layer Quality Control in Thermoplastic Extrusion in Additive Manufacturing
Reinforcement Learning for Energy-Efficient Toolpath Generation in Additive Manufacturing
Research on Influence of Scan Strategy on Part Shrinkage in Low Temperature Laser Sintering of Polymer
Residual Stress Evaluation of EB-PBF Produced High Strength Mo-7Re-1HfC Alloy via Neutron Diffraction
Robotic Convergent Manufacturing of Large Format Structures
Shape Memory Alloy Enabled Interlocking Metasurfaces by L-PBF
Simulation and Estimation of Mechanical Properties of Additively Manufactured Metal Components
Size and Shape Optimisation for High-Performance Battery Electrodes
Size Effect on Porosity of Thin Struts Fabricated by Laser Powder-Bed Fusion (L-PBF)
Smooth 3D Transition Cell Generation based on Latent Space Arithmetic
Sol-Gel Synthesis Integrated 3D Printing of Lithium Nickel Cobalt Manganese Oxide
Solar Harvesting and Photothermal Energy Generation via Multiple Transparent Plasmonic Fe3O4@Cu2-xS Thin Films
Soldering and Electroplating to AM Surfaces
Spreadability of Raw Sand in Binder Jet Additive Manufacturing: Examining Feasibility Using Numerical Methods
Statistical Process Control for WAAM for Productivity and Quality Improvements
STEAM Powered: An Argument for the Robust Integration of Artistic and Engineering Practices in Design for Additive Manufacturing
Stop Building Naked Lattices! A (More Than) Modest Mechanical Property Improvement Strategy
Strategizing Scan Technique Selection for Component Remanufacturing Using 3D Printing: A Combined Reverse Engineering and TOPSIS Based Multi Criteria Decision Making Framework
Study of Additively Manufactured Tungsten and Tungsten alloys via Laser Based - Directed Energy Deposition Process for High Temperature Applications
Study of Using a Secondary Pulsed Laser for Process Control in Laser Powder Bed Fusion
Surface Roughness Measurements of Additively Manufactured Components via X-Ray Computed Tomography
Surface Roughness of the Micro Milled 3D Printed 316L Stainless Steel Parts Fabricated by FDM/ FFF Technology
Sustainable Waste Management In Additive Manufacturing: Old And New Strategies To Divert Industrial Waste From Landfills
Symmetric Build Plate Deposition: A Strategy to Mitigate Solidification-Induced Residual Stresses in DED-Arc Additive Manufacturing
Synchrotron-based In Situ/Operando Characterization Capabilities at NSLS-II
Synergizing Machine Learning and Multiphysics Simulation for Spatter Process Map Generation in LPBF Processes
Temperature Control of Digital Glass Forming Processes
Tensile and Fatigue Analysis of Functionally Graded Materials with Varying Concentrations Manufactured Using Material Extrusion
The Behaviour of First-Generation Bio-Composites in a Multi-Axis Material Extrusion Application
The Development of a Precise Quick Response Apparatus for Functional Grading in Reactive Extrusion Additive Manufacturing
The Effects of Laser Absorption and Shielding in Plasma Vapor Jets Induced by Continuous Wave Laser Irradiation of Tungsten
The Effects of Multi-laser Process Parameters in LPBF Manufactured Inconel 718
The Impact of Different HIP Treatment Cycles on Fatigue Behavior during 4-Point Bending of Additively Manufactured (AM) Ti-6Al-4V
The Influence of Contour Offset in Laser Powder Bed Fusion
Thermal-Assisted Direct Ink Write 3D Printing of Stainless Steel 316L Colloidal Pastes
Thermal and Mechanical Characterization of Lightweight PLA Filaments for Material Extrusion
Thermal Emission-Based Geometric Mapping of Specular Glass Surfaces
Thermographic Porosity Estimation by Monitoring Non-Uniformity of Intra-Layer Cooling During Hybrid Directed Energy Deposition
Titanium Wire Arc Additive Manufacturing Inert Enclosure and Material Handling Safety Considerations
Toolpath Planning for Additively Manufactured Continuous-Fiber Reinforced Composties Designed by Topology Optimization
Topology-Driven Information Embedding in Structural Components
Topology Optimisation of Bespoke Lattice Orthopaedic Implants
Topology Optimised Multi-Material MBB Beam Fabricated via Powder Bed Fusion
Toward In-Situ Sensing of Powder Packing Density In metal Binder Jetting Using Recoating Force
Toward Parametric Heat Transfer Solvers in Additive Manufacturing
Toward Rapid Process Qualification of Laser Powder Bed Fusion Additive Manufacturing Using Physics-Based Model Predictive Control
Toward Real-Time Adaptive Material Control in Large-Scale Robotic Additive Manufacturing
Toward SmartScan 2.0 - An Intelligent Scanning Sequence Optimization Method for Reduced Part Deformation and Residual Stress in LPBF Based on Thermo-Mechanical Models
Towards Affordable Aluminum Additive Manufacturing: Considerations on the Manufacturing of Non-Explosible NExp-1 AlSi10Mg on Medium-Wattage Systems
Towards an Analytical Model for Multi-Objective Optimization of Cellular Materials
Towards Experimentally-Informed Modeling of Conduction for Improved Finite Element Thermal Prediction of Wire-Arc Directed Energy Deposition
Towards Freeform Additive Manufacturing: Recent Improvements Made on ORNL Large Scale Metal Slicer to Meet the Challenges brought by Growing Complexity of Parts in Wire-arc Additive Manufacturing
Towards High Resolution and High Speed Metal AM with Molten Metal Droplet Jetting
Towards Sustainable Fabrication of Electronics via Molten Metal Jetting
Towards Sustainable Rechargeable Batteries via Single Point Exposure Laser Powder Bed Fusion of Pure Zn Lattice Structures
Towards the Feasibility Analysis and Additive Manufacturing of a Novel Flexible Pedicle Screw for Spinal Fixation Procedures
Ultrasonic Vibration Augmented Fused Deposition Modeling through Step-wise Contour Scanning
Understanding Melt Pool Variation Due to Geometric Features and Scan Pathing
Understanding Melt Pool Variation Due to Geometric Features and Scan Pathing
Understanding Microstructure and Oxide Distribution in ODS Steels through Thermodynamic Simulations and Melt Pool Analysis in LPBF Processes
Understanding the Impact of Printing Strategies on Drop-on-Demand Molten Metal Jetting Technologies
Universal Differential Equations for Transient Thermal Modeling of Directed Energy Deposition Additive Manufacturing
Unsupervised Multi-Modal Machine Learning for In-Process Monitoring of Additive Manufacturing
Unveiling Gas–Liquid Metal Reactions in Metal Additive Manufacturing: High-Fidelity Modeling Validated with Experiments
Unveiling Spot Melting Strategies for Microstructure Control in Electron Beam Powder Bed Fusion
Upcycling Machining Chips for Additive Friction Stir Deposition Feedstock Production
Use of an Acousto-Optic Deflector Light Engine to Improve Resolution and Speed of the Stereolithography Process
Use of Cored Wire in the Optimisation of New Alloys for Laser Powder Bed Fusion with Tailored Mechanical and Corrosion Properties
Using Laser Ultrasonics to Measure Localized Changes in Young’s Modulus caused by Select Laser Flash Sintering
Using Trilinear Coordinate Measurements to Inform Prior Models for Minimally-Invasive Material Extrusion Path Planning
Variations Across Length Scales in Additively Manufactured Ti- 6Al-4V Parts: Challenges to Repeatability and Reproducibility
Vector-Level Feedforward Control of LPBF Melt Pool Area Using a Physics-based Thermal Model
Wire Arc Additive Manufacturing of Multi-material Parts Using H-13 Tool Steel
Wire Feed Speed Based Layer Height Controller for Wire Arc Additive Manufacturing
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