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We present a novel computational paradigm for process design in manufacturing processes that incorporates simulation responses to optimize manufacturing process parameters in high-dimensional temporal and spatial design spaces. We developed a differentiable finite element analysis framework using automatic differentiation which allows accurate optimization of challenging process parameters such as time-series laser power. We demonstrate the capability of our proposed method through three illustrative case studies in additive manufacturing for: (i) material and process parameter inference using partial observable data, (ii) controlling time-series thermal behavior, and (iii) stabilizing melt pool depth. This research opens new avenues for high-dimensional manufacturing design using solid mechanics simulation tools such as finite element methods. Our codes are made publicly available for the research community at https://github.com/mojtabamozaffar/differentiable-simulation-am.

Toolpath optimization of metal-based additive manufacturing processes is currently hampered by the high-dimensionality of its design space. In this work, a reinforcement learning platform is proposed that dynamically learns toolpath strategies to build an arbitrary part. To this end, three prominent model-free reinforcement learning formulations are investigated to design additive manufacturing toolpaths and demonstrated for two cases of dense and sparse reward structures. The results indicate that this learning-based toolpath design approach achieves high scores, especially when a dense reward structure is present., Comment: 8 pages, 4 figures

Additive Manufacturing (AM) is a manufacturing paradigm that builds three-dimensional objects from a computer-aided design model by successively adding material layer by layer. AM has become very popular in the past decade due to its utility for fast prototyping such as 3D printing as well as manufacturing functional parts with complex geometries using processes such as laser metal deposition that would be difficult to create using traditional machining. As the process for creating an intricate part for an expensive metal such as Titanium is prohibitive with respect to cost, computational models are used to simulate the behavior of AM processes before the experimental run. However, as the simulations are computationally costly and time-consuming for predicting multiscale multi-physics phenomena in AM, physics-informed data-driven machine-learning systems for predicting the behavior of AM processes are immensely beneficial. Such models accelerate not only multiscale simulation tools but also empower real-time control systems using in-situ data. In this paper, we design and develop essential components of a scientific framework for developing a data-driven model-based real-time control system. Finite element methods are employed for solving time-dependent heat equations and developing the database. The proposed framework uses extremely randomized trees - an ensemble of bagged decision trees as the regression algorithm iteratively using temperatures of prior voxels and laser information as inputs to predict temperatures of subsequent voxels. The models achieve mean absolute percentage errors below 1% for predicting temperature profiles for AM processes. The code is made available for the research community at https://github.com/paularindam/ml-iter-additive., Comment: 10 pages, 8 figures