State-of-the-art of numerical simulation of laser powder Directed Energy Deposition process

Additive manufacturing (AM) has been experiencing considerable growth in recent years, especially for metal application. Directed Energy Deposition (DED) is one of the emerging technologies in metal AM. DED selectively deposits material and melts it with a focused high-energy source. Accurate numerical modelling of the DED technique is an important step for the comprehension and the technological improvement of the process, providing significant gains in terms of time and costs. This paper aims to review the existing knowledge on DED numerical simulation, highlighting principal advantages and limitations of different approaches. The key inputs required to model the process properly, and the predictable outcomes are discussed.