Simulation-based Optimisation Of Selective Laser Sintering/Melting Process

In order to adapt Selective Laser Sintering (SLS) and Melting (SLM) to final products and volume production, many scientists have turned to statistical analysis for quality and process stability. Most of which are based on extensive experiments aiming at finding statistical correlations between input parameters such as layer thickness, orientation, scan speed, powder bed temperature, laser power... and resulting strength and residual stress of the manufactured part. However, the rise of computer simulation based on mathematical models allows predictions at a much lower cost. Mathematical modelling of SLS/SLM involves molecular level thermodynamics and thermo-mechanical behaviour of the powder material. In this study, we employ the newly developed Extended Discrete Element Model to reproduce the SLS process including the mechanisms of sintering and the evolution of fracture properties and self-supporting ability. Results show that such microscale model offers high precision and flexibility for finding optimal process parameters.