Machine learning predictions of spatter behavior in LPBF additive manufacturing

The adoption of additive manufacturing (AM) technologies, particularly Laser Powder Bed Fusion (LPBF), has been rapidly increasing in industries requiring high precision and complex geometries. Despite its advantages, LPBF faces challenges related to defects that affect material quality, with spatter formation being a significant concern. Spatters – tiny particles ejected during the printing process – can adversely affect the final product’s integrity by altering surface roughness and contributing to defects. This study introduces a comprehensive approach to predict the ejection velocity and direction of spatter particles using a suite of machine learning (ML) algorithms, including Random Forest, Gaussian Process Regression, Support Vector Machine, Regularized Linear Regressions, Gradient Boosting Trees, and Neural Networks. Our analysis reveals that the Neural Network model outperforms others, achieving prediction accuracies of 97.58% for spatter velocity and 88.22% for ejection direction, thus offering a substantial improvement in understanding and controlling spatter-related defects in LPBF processes. The practical implications of these predictions are profound, enabling manufacturers to adjust AM parameters in real time to minimize defects and enhance product quality. This study not only fills a gap in the current literature by providing a detailed comparative analysis of multiple ML algorithms for spatter ejection prediction but also paves the way for future research into real-time monitoring and control systems in AM.