Finding the processing conditions which can produce high density components using Selective Laser
Melting (SLM) technique based on trial-and-error is costly and time consuming. With a given SLM machine
characteristics (e.g., laser power, scanning speed, laser spot size and laser type), powder material and powder
size distribution, the present study proposes an approach to reduce the time and cost in searching optimal
parameters for fabricating fully dense parts. The proposed method include several simulation models which are
powder bed simulation, Monte Carlo ray tracing simulation, Finite Element Heat Transfer simulation and
surrogate modeling. These simulation models are employed to find the viable processing parameters to produce
high density component. The experimental results show that the proposed methods results in a maximum
component density of 99.97%, an average component density of 99.89% and a maximum standard deviation of
0.03%.Mechanical Engineerin
