Physics-aware feedforward dwell time adjustment for mitigating distortion in additively manufactured cantilevers

Heterogeneous temperature distributions in additively manufactured metallic parts, particularly in laser powder bed fusion (PBF-LB/M), pose a major challenge to achieving high-quality components due to thermal distortions, microstructural inconsistencies, and shifts in the process window. This study introduces a physics-aware feedforward approach for regulating dwell time that effectively mitigates distortion in 3D-printed cantilevers by reducing thermal variations along the build direction. A fast, 1D finite volume method thermal simulation is employed to estimate the temperature profile throughout the build. The interlayer dwell time is dynamically adjusted based on a predefined thermal difference threshold between layers to minimize residual stresses and part deformation. Experimental validation on a cantilever beam geometry confirms that the adaptive dwell time strategy significantly reduces distortion compared to a constant dwell time approach. The proposed method enhances thermal stability while maintaining processing times, offering an efficient solution for distortion control in PBF-LB/M. These findings contribute to advancing process optimization strategies by integrating physics-based thermal modeling with feedforward control.