Optimized Build Plate Design Tool for Metal Laser Powder Bed Additive Manufacturing

Build plate optimization is a challenge in additive manufacturing requiring multiple iterations to optimize part and support structure configurations to minimize residual stress. Currently, computational build volume optimization consider efficient bed packing above the build plate in 3 dimensions without optimizing global residual stress. Thus, multiple experimental iterations are required to eliminate cracks arising from tensile residual stresses. Similarly, support generation algorithms are not optimized for efficient heat transfer and multiple experimental iterations are needed to optimize for the best configurations. 3DSIMs exaSIM software creates support structures which can counteract local residual stress, however the support structures are not designed for efficient heat transfer and minimization of residual stresses. Additive manufacturing is severely hampered due to these issues, and there is a need to fabricate parts right the first time to enable widespread industrial adoption. The proposed work will result in validated build optimization tools which minimize global and local residual stress. These algorithms enable fabrication of non-generic, non-linear topologically optimized contact and non-contact support structures for better heat transfer and 3-Dimensional part nesting. Phases II and III will investigate changes in defect and mechanical property distributions due to these non-traditional supports, giving the Navy an all-inclusive build optimization tool.