CFD Simulation of Powder Directed Energy Deposition (DED)

Uploaded July 2024 | Updated September 2026, 1 week ago

In this powder directed energy deposition (DED) simulation, two powder feed nozzles direct metal particles toward a laser source which heats them enough to liquefy. This leaves a single track of deposited material on top of a base plate. The animation is colored by temperature, with red being the hottest and blue being the coolest. To learn more about how FLOW-3D AM allows for full consideration of powder composition (up to two different materials), catchment efficiencies, build directions and laser and substrate orientation, visit flow3d.com/products/flow3d-am/.

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$Powder Directed Energy Deposition Additive Manufacturing - Bead Geometry Modelling | FLOW-3D AM In this simulation, the Computational Fluid Dynamics (CFD) model of FLOW-3D AM was used to predict the morphology of the bead in DED Additive Manufacturing. The simulation captures the dilution of newly deposited material into the previous layer or substrate. Moreover, the temperature, solid fraction, and velocity inside the melt pool are calculated which gives a detailed picture of the bead formation in this metal 3D printing process. To learn more about how you can use FLOW-3D AM to analyze and predict melt-pool dynamics and solidification in AM processes such as LPBF and DED, visit https://www.flow3d.com/products/flow3d-am/.$

$Melt Pool Simulation of Overhang Dross in Laser Powder Bed Fusion (LPBF) | FLOW-3D AM This laser powder bed fusion (LPBF) simulation animation shows 3 melt tracks as the laser beam approaches a down-facing overhang surface that runs parallel to the laser motion. The lack of structural support beneath the overhang surface causes the melt pool to sink lower than its neighboring layers, producing an effect called Dross. Naturally, dross formation causes dimensional inaccuracy, high surface roughness and also adversely affects the mechanical properties of printed components. FLOW-3D AM is used to quantify process parameters to reduce defects like dross. Learn more about how FLOW-3D AM can be used for LPBF simulations and more by visiting https://www.flow3d.com/products/flow3d-am/. Top left: Temperature field in degree C Top right: Solid fraction Bottom left: Top view using ray-tracing to visualize metallic material Bottom right: Front view using ray-tracing to visualize metallic material$

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