Xia Qing, Yu Qian, Li Yibao
Component design (“digitalization”), performance optimization (“optimization”), and process simulation (“simulation”) are three critical modules in the 3D printing process. “Digitalization” refers to the transformation of design drawings or pre-processed physical objects into editable digital components through means such as images, videos, and scanning processes. “Optimization” involves the application of constraints from physical fields such as mechanics and thermodynamics to enhance the performance of digital components. “Simulation” entails the digital simulation and twin modeling of physicochemical changes during the manufacturing process, based on the optimized components, to emulate real-world physical conditions. This research aims to introduce integrated modeling and algorithmic studies in design, optimization, and simulation within the phase field framework. In the “digitalization” module, we will present three-dimensional reconstruction models, repair models, and lightweight support structure design models that correspond to common data types in computer-aided design. In the “optimization” module, we will introduce a series of multi-scale, multi-physical field, and multi-material coupled topology optimization problems and their corresponding solutions. In the “simulation” module, we will discuss macroscopic (phase transition) to microscopic (grain boundary) scale coupling theories and the physical field couplings such as laser-thermal-flow-solid, in addition to simulating methods for processes like Fused Deposition Modeling (FDM) and Selective Laser Melting (SLM), integrating 3D printing parameters and techniques. The integrated research approach to design, optimization, and simulation based on the phase field model framework aims to shorten the product development cycle, enhance design efficiency, and provide a theoretical basis and algorithmic support for quality traceability and root cause analysis of 3D printed components.
