Digital Workflow Analysis of LPBF Systems via Software Performance Evaluation Using Parametric Test Artifacts

Laser Powder Bed Fusion depends on build file preparation software to create laser scanner toolpaths and interpret environment parameters, establishing the digital workflow of a metal 3D printed part a crucial aspect of part quality. Parameters from LPBF prints have been widely studied in the post-printing process but a gap exists for the analysis of the digital interpretation of parameter adjustments across LPBF machine environments. This thesis aims to address this gap in a two-stage evaluation of four LPBF build preparation software packages. In Stage 1, software usability and workflow efficiency are examined through user training by assessing software workflow clarity and ease-of-use in tool accessibility. Stage 2 evaluated how each software interpreted four key printing parameters through modification interpretations. Obtained digital build files were analyzed through selected features of two machine qualification models with quantifiable and qualifiable methods. Results displayed perspective differences in software behavior and task performance across each software package, with insights on user satisfaction and software reliability. Findings also indicate differences in scan path representation across identical arrangements that suggest potential variability and require further evaluation for the purposes of optimization. This study provides an initial approach into evaluating LPBF software behavior through several aspects and highlights an overlooked area influencing print replicability, suggesting a need for more thorough standardization across LPBF build preparation practices.