Scalable Thermal Simulation of Powder Bed Fusion

Powder bed fusion (PBF) has become a widely used additive manufacturing (AM) technology to produce metallic parts. In PBF, thermal field evolution during the manufacturing process plays an important role in determining both geometric and mechanical properties of the fabricated parts. Thermal simulation of the PBF process is computationally challenging due to the geometric complexity of the manufacturing process and the inherent computational complexity that requires a numerical solution at every time increment of the process. We propose a new thermal simulation of the PBF process based on the laser scan path. Our approach is unique in that it simulates the thermal history of the process on the discretization of the geometry implied by the process plan (i.e., scan path), as opposed to voxelization or meshing of the design geometry. The discretization is based on the laser scan path, and the thermal model is formulated directly in terms of the manufacturing primitives. An element growth mechanism is introduced to simulate the evolution of the melt pool during the manufacturing process. A spatial data structure, called contact graph, is used to represent the discretized domain and capture all thermal interactions during the simulation. The simulation is localized through exploiting spatial and temporal locality. This limits the need to update to at most a constant number of elements at each time-step, which implies that the proposed simulation not only scales to handle three-dimensional (3D) printed components of arbitrary complexity but also can achieve real-time performance. The simulation is fully implemented and validated against experimental data and other simulation results.