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San Francisco's Golden Gate Bridge is exposed to temperatures ranging from -15 °C to 40 °C. At its coldest, the main span of the bridge is 1275 m long. Assuming that the bridge is made entirely of steel, what is the change in its length between these temperatures?
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Integrating Orientation Optimization and Thermal Distortion Prediction in LPBF: A Validated Framework for Sustainable

Nikoletta Sargioti1, Elias P Koumoulos2, Evangelia K Karaxi1

  • 1Conify, P. Nikolaidi 23A, Agios Ioannis Rentis, 182 33 Athens, Greece.

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Summary

Optimizing build orientation in laser powder bed fusion (LPBF) impacts thermal distortion and residual stress. Balancing print time, support volume, and surface area is key for efficient, cost-effective, and sustainable manufacturing.

Keywords:
additive manufacturinglaser powder bed fusionpart orientation optimizationsustainabilitythermal distortion prediction

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Area of Science:

  • Materials Science and Engineering
  • Additive Manufacturing
  • Computational Materials Science

Background:

  • Laser Powder Bed Fusion (LPBF) is a critical additive manufacturing technology.
  • Build orientation significantly influences part quality, including thermal distortion and residual stresses.
  • Optimizing orientation is essential for process efficiency and cost reduction.

Purpose of the Study:

  • To investigate the impact of different build orientation strategies on thermal distortion, residual stress, and process efficiency in LPBF.
  • To evaluate simulation accuracy in predicting distortion compared to experimental data.
  • To analyze the cost and environmental implications of various orientation strategies.

Main Methods:

  • Generation of four orientation strategies (surface area, support volume, print time, overheating) using Siemens NX.
  • Prediction of distortion using Atlas 3D simulation software.
  • Experimental validation via 3D scanning for surface deviation analysis.
  • Sustainability and cost analysis, including CO2 emissions and energy consumption.

Main Results:

  • Support volume and print time optimized orientations showed minimal in-process distortion but higher post-removal deformation due to stress relaxation.
  • Surface area optimization led to greater in-process distortion but more stable post-processing behavior.
  • Atlas 3D simulations closely matched experimental 3D scan data, accurately identifying critical distortion zones.
  • Surface area optimization offered the greatest cost and CO2 reduction; support volume and print time strategies also yielded significant savings.

Conclusions:

  • Build orientation selection in LPBF critically affects thermal distortion, residual stress, and overall process efficiency.
  • Integrating simulation tools like Atlas 3D with cost and environmental metrics is vital for informed orientation choices.
  • Optimized orientations can lead to substantial reductions in production costs and environmental impact, enhancing LPBF manufacturing sustainability.