Advancements and Challenges in Additive Manufacturing: A Roadmap for Enhanced Finite Element Modeling and Process Optimization

Additive Manufacturing (AM) processes usually have nonlinearities like material properties, geometrical deformations, contact interactions and substantial displacements. These nonlinearities can make the problem-solving process more complicated and thus, it would be difficult to predict the consequences of the process. The finite element method, generally known as FEM, is a famous numerical technique that is applied to model complex physical phenomena and the materials’ behavior during the manufacturing process. This design supports the choice of manufacturing strategies that help a person avoid mistakes and hence save money. As for the computationally predicting of AM processes, PFEM is the most liked process in the computational world that brings about better accuracy, precision and shorter computing time. The future engineering problems which will be solved with AM in Finite Element Modeling (FEM) will be the result of the advancements in computational power, topology optimization, complex analyses, reliability and constraints, and new simulation methods. The main purpose of the roadmap for the evolution of AM technology will be to improve the capabilities and applications of AM technologies. This roadmap is geared toward the transition from digitalization to intellectualization, innovation and industrialization.