Residual Temperature Prediction in Selective Laser Melting by Deep Neural Networks

Selective laser melting (SLM) builds metal parts layer by layer by locally melting powder with a fine laser beam, generating complex, geometry-dependent temperature gradients that govern density, microstructure, defects, and residual stresses. Resolving these gradients with high-fidelity finite-element (FE) models is prohibitively slow because the temperature field must be evaluated at dense points along every scan track across multiple layers, while the laser spot is orders of magnitude smaller than typical layer dimensions. This study replaces FE analysis with a deep neural network that predicts the end-of-build temperature field orders of magnitude faster. A benchmark part containing characteristic shape features is introduced to supply diverse training cases, and a novel control-volume-based geometry-abstraction scheme encodes arbitrary workpiece shapes into compact, learnable descriptors. Thermal simulation data from the benchmark train the network, which then predicts the residual temperature field of an unseen, geometrically dissimilar part with a mean absolute error of ~10 K and a mean relative error of ~1% across 500–1300 K. The approach thus offers a rapid, accurate surrogate for FE simulations, enabling efficient temperature-driven optimization of SLM process parameters and part designs.