In this study, a thermal management simulation for powder bed fusion – laser beam/ metals (PBF-LB/M) is introduced, optimizing the inter-layer waiting times to enhance multi-laser processes. PBF-LB/M can be scaled up with multi-laser systems for increased productivity. However, this scaling alters the thermal history of parts, impacting mechanical integrity, microstructure, and potential defects.

The development of an algorithm for calculating adaptive waiting times to maintain predefined temperatures after each layer's completion is a significant step forward. This algorithm, integrated into a fast thermal simulation using layer lumping, the combined activation of several process layers, has practical implications for the industry. The model has been applied to a multi-laser machine, assessing the advantages of adaptive cooling over minimal layer times. Findings indicate that adaptive cooling achieves lower peak temperatures more efficiently. Nevertheless, the extended manufacturing time indicates that active cooling mechanisms will be necessary to maximize the potential of multi-laser systems.

In conclusion, this paper underscores the critical importance of thermal management, particularly the adjustment of inter-layer waiting times, in maintaining the quality and functionality of PBF-produced metal parts. Our findings emphasize the urgent need for effective thermal management strategies in the industry.