Assessment of simulation software for predicting induced distortions in laser-beam powder bed fusion of Ti6Al4V

The right first time (RFT) in the laser-beam powder bed fusion of metal powder (PBF-LB/M) process refers to achieving optimal part quality and minimal distortions in the first manufacturing attempt, which is critical for enhancing productivity and sustainability. This is particularly challenging due to the internal stresses and thermal gradients inherent to the process, which lead to significant distortions. This study addresses the challenge of predicting and mitigating these distortions for Ti6Al4V parts in the PBF-LB/M process. Calibration tests and experimental validations using Amphyon software were conducted, with the process involving software calibration, sensitivity analysis, and simulation validation through reverse engineering tools. Additionally, a pre-compensation method was applied to monitor and reduce distortion. The results demonstrated that Amphyon can predict distortions with a maximum deviation of up to 14% between simulated and experimental results, while pre-compensation reduces deformation by up to 70%. Finally, the simulation approach was validated through a real-world application, fabricating a cranial medical implant, showcasing its practical relevance. This work highlights the potential of simulation tools for optimizing PBF-LB/M processes, improving accuracy, and reducing material waste in industrial applications.