Perspectives of using machine learning in laser powder bed fusion for metal additive manufacturing

ABSTRACT

The adoption of laser powder bed fusion (L-PBF) for metals by the industry has been limited despite the significant progress made in the development of the process chain. One of the key obstacles is the inconsistency of the parts obtained from L-PBF. Due to its complexity, there are many potential fluctuations that can occur within the process chain which can lead to quality inconsistency in L-PBF parts. Machine learning (ML) has the possibility to overcome this obstacle by utilising datasets obtained at various stages of the L-PBF process chain. In this perspective article, the integration of ML into the different stages of L-PBF process chain, which potentially lead to better quality control, is explored. Prior to L-PBF, ML can be used for part designs and file preparation. Then, ML algorithms can be applied in the process parameter optimisation and in situ monitoring. Finally, ML can also be integrated into the post-processing.

KEYWORDS:

• Additive manufacturing
• 3D printing
• powder bed fusion
• selective laser melting
• artificial intelligence
• machine learning

Disclosure statement

No potential conflict of interest was reported by the author(s).

Additional information

Notes on contributors

S. L. Sing

Dr S. L. Sing is a Presidential Postdoctoral Fellow at the Singapore Centre for 3D Printing and School of Mechanical and Aerospace Engineering, Nanyang Technological University, Singapore. His research interest is enabling material development and creating strategic values for the industry through advanced manufacturing. His doctoral thesis focuses on laser powder bed fusion of a novel titanium alloy for medical applications. The doctoral thesis and related research are awarded the Best PhD Thesis Award by the School of Mechanical and Aerospace Engineering, Nanyang Technological University, Singapore and the Springer Theses Award in 2017. In 2020, he is awarded the prestigious NTU Presidential Postdoctoral Fellowship to carry out independent research. As of June 2021, he has co-authored 44 peer reviewed articles in the field of additive manufacturing or 3D printing. He currently has a h-index of 25, with more than 3000 citations, and is also the co-inventor for three patents on the powder bed fusion process.

C. N. Kuo

Assistant Professor C. N. Kuo is an Assistant Professor in the Department of Bioinformatics and Medical Engineering, Asia University, Taichung, Taiwan. He received his PhD from Department of Materials and Optoelectronic Science, National Sun Yat-sen University in 2013. He conducted metal 3D printing research and built up the Electron Beam Additive Manufacturing Laboratory at Metal Industries Research & Development Centre from 2013 to 2017 before taking his current position at Asia University. Prof Kuo is now conducting research in 3D Printing Medical Research Institute hosted at Asia University, Taichung, Taiwan. He is also the Head of the Selective Laser Melting Laboratory at the 3D Printing Medical Research Center, China Medical University Hospital, Taichung, Taiwan. His current research focuses on the 3D printing parameters of advanced metallic materials, mechanical behaviour of porous materials, development and optimization of post/heat treatments for porous materials, and the microstructure evolution research of advanced materials during/after 3D printing process.

C. T. Shih

Assistant Professor C. T. Shih is an Assistant Professor in the Department of Biomedical Imaging and Radiological Science, China Medical University, Taichung, Taiwan and a Research Fellow at the x-Dimension Center for Medical Research and Translation, China Medical University Hospital, Taichung, Taiwan. He currently focuses on algorithm development for optimal porous structure design and rapid mechanical analysis. These algorithms have been applied in the design of various components and products of machinery, healthcare, and national defence, including bicycle head tubes and pedals, shoe midsoles and insoles, turbine, cervical cages, and mandible implants.

C. C. Ho

Assistant Professor C. C. Ho is an Assistant Professor in the Department of Bioinformatics and Medical Engineering, Asia University, Taichung, Taiwan. He has published 31 refereed articles in the fields of biomaterials science and tissue engineering, and he has a h-index of 17 (Google Scholar). His research interests are dedicated to developing osteoconductive bio-metals and bio-ceramics by means of bio-inspired surface modifications and biomineralization strategies, respectively, as well as preparations of biocompatible, biodegradable, and bioprintable hydrogel systems for tissue engineering applications.

C. K. Chua

Professor C. K. Chua is the Head of Pillar for Engineering Product Development and Cheng Tsang Man Chair Professor at the Singapore University of Technology and Design (SUTD), Singapore. Prof Chua is an active contributor to the field of additive manufacturing (or 3D printing) for over 30 years and is highly regarded by the scientific community. He won the prestigious International Freeform and Additive Manufacturing Excellence (FAME) Award in 2018. Prof Chua is also the Editor-in-Chief of ‘Virtual and Physical Prototyping' and ‘International Journal of Bioprinting'. As of June 2021, he has contributed more than 400 technical papers, generating more than 16,000 citations (with h-index of 65), and co-authored five books including ‘3D Printing and Additive Manufacturing: Principles and Applications (5th edition)’ and ‘Bioprinting: Principles and Applications’.