Optimization of the Design and Manufacturing Processes for Metal Additive Manufacturing Through Digital Twin

The aim of this study is to develop a digital twin hierarchy that fully examines the design and manufacturing processes of an automotive component for metal additive manufacturing. Initially, a lighter model was obtained that was more resistant to static, dynamic, and fatigue loads under various operating conditions. This step improved product strength and resulted in a 28.5% mass reduction. After the product was validated, the orientation of the part direction and the generation of support structures were performed for the manufacturing process. These processes were implemented with the criterion of minimizing production time. Finally, the manufacturing process was digitally implemented using the selective laser melting method and Ti6Al4V material. The design of the experiment was created using the three most frequently preferred values for each of the three important process parameters. After performing process simulations with thermomechanical analyses, Taguchi and ANOVA were applied to the process parameters. The optimum process parameters for layer thickness, hatch spacing, and scanning speed were found to be 50 µm, 120 µm, and 1200 mm/s, respectively.