A review of computer simulations of metal 3D printing

The metal 3D printing technologies are a joining materials process to create the metal 3D parts through CAD model, usually layer by layer, as opposed to subtractive manufacturing. This technology can be classified into four methods: selective laser melting (SLM), binder jetting, materials extrusion and direct energy deposition (DED). The process has advantages for producing near net shape parts, complex topology parts, lattice structure parts, manufacturing tool, medical parts, aerospace parts, and automotive parts. Over the last decade, the metal 3D printing simulation models were developed to investigate and predict the physical phenomena, thermo-mechanical behavior, and performance of metal 3D printing parts in the metal 3D printing technologies. The present study aims to review the computer simulation of metal 3D printing technologies. This review paper focuses on the numerical modelling and simulation in metal 3D printing process, recent simulation case studies and trends in metal 3D printing which are involved with the process parameters, temperature distribution, heat transfer, fluid dynamics, microstructure, porosity, melt pool characteristics and residual stress. The information obtained from this study will be useful for the further research studies in the metal 3D printing technologies.