SLM (Near)-Net-Shape part design optimization based on numerical prediction of process induced distortions

Abstract

Distortions are critical in metal additive manufacturing, since they increase manufacturing costs, times and generate wastes and scraps due to dimensional inaccuracies in newly developed parts. Currently, corrective measures are often not taken until production step and they are mainly based on trial an error approach. Alternatively, Design Against Distortion paradigm is focused on the development of numerical modelling strategies which can anticipate distortions even from the design stage. This work is focused on the development of a rapid distortion prediction numerical methodology applicable to selective laser melting (SLM) process, taking into account the influence of different process variables, like scanning parameters and scanning strategy. This methodology is applicable to predict distortion behaviour of a real component manufactured by SLM, in order to determine the best supporting strategy and build up orientation. Therefore, current developments entail an innovative way of designing and manufacturing SLM manufactured parts which are more robust against distortions.