The laser powder bed fusion (LPBF) process is a widely used additive manufacturing technique for metals where precise temperature control is critical for ensuring material quality and process stability. This study presents a comprehensive investigation combining both numerical simulation and experimental temperature measurement within the LPBF process. The simulation is conducted using the super-layer approach within the Ansys Mechanical software, which enables an efficient and time-saving representation of the thermal phenomena on a part scale level. The thermal model simulates the spatiotemporal temperature changes in form of heating and cooling rates as well as the absolute temperatures depending on the geometry.

To validate the simulation, a temperature measurement device was designed, built, and integrated into the system for LPBF. The device employs up to four thermocouples to capture real-time temperature data during the process. The height of the thermocouples is adjusted layer by layer using a servomotor. This experimental setup allows for continuous monitoring of thermal profiles, providing a valuable dataset for direct comparison with simulation results.

The temperature profiles obtained from the simulation are analyzed and compared to the experimentally recorded data. Initial results demonstrate a high correlation between the simulated and measured temperatures, with deviations primarily attributed to simplifications in the model and limitations of the thermocouple placement. The comparison provides critical insights into the accuracy and limitations of the super-layer approach for LPBF process simulations. Furthermore, it is also possible to use the temperature measuring device to measure the temperature of slightly modified series components manufactured using LPBF. The findings contribute to improving the predictive capabilities of thermal models in additive manufacturing, enabling enhanced control and optimization of the LPBF process.