This work presents a novel process design optimization framework for additive manufacturing (AM) by integrating physics-informed computational simulation models with experimental observations. The proposed framework is implemented to optimize the process parameters such as extrusion temperature, extrusion velocity, and layer thickness in the fused filament fabrication (FFF) AM process, in order to reduce the variability in the geometry of the manufactured part. A coupled thermo-mechanical model is first developed to simulate the FFF process. The temperature history obtained from the heat transfer analysis is then used as input for the mechanical deformation analysis to predict the dimensional inaccuracy of the additively manufactured part. The simulation model is then corrected based on experimental observations through Bayesian calibration of the model discrepancy to make it more accurately represent the actual manufacturing process. Based on the corrected prediction model, a robustness-based design optimization problem is formulated to optimize the process parameters, while accounting for multiple sources of uncertainty in the manufacturing process, process models, and measurements. Physical experiments are conducted to verify the effectiveness of the proposed optimization framework.
Keywords: Additive manufacturing; Experimental validation; Fused filament fabrication; Material extrusion; Process design.