Minimizing part deformation in laser deposition by evolutionary optimization of laser beam path

Potočnik, Primož (author), Nair, Anish (author), Jeromen, Andrej (author), Govekar, Edvard (author)

Purpose – The purpose of this paper is to apply an innovative evolutionary approach based on a genetic algorithm (GA) for optimizing laser beam (LB) paths in laser-based additive manufacturing (LBAM) with the aim of minimizing deformation of the manufactured part and demonstrating the proposed approach by finite element modeling (FEM) simulations. Design/methodology/approach – The study introduces a GA-based evolutionary approach for optimizing LB paths in LBAM processes. The optimization of the LB path is a critical factor influencing the quality of the additively manufactured part and the efficiency of the additive manufacturing (AM) process. This study approaches the problem by formulating the LB path optimization as a search for the optimal sequence of material deposition on a thin metal plate. The optimization objective is defined by a fitness function, which can be composed of various components. FEM simulations are applied to calculate the deformation of the metal plate due to laser deposition, based on which the fitness is calculated. Findings – The findings of this study, using the thermo-mechanical simulation results, indicate the improvements in the final geometry of the metal plate, e.g. decrease in the plate deformation, if the LB path is optimized. The GA-based optimization approach for the LBAM process exhibits improvement over traditional trial-and-error LB path formulations due to the automation of the LB path selection and optimization. Therefore, the proposed approach provides an efficient automated selection of LB paths in LBAM. Research limitations/implications – The study investigates the methods of optimizing the LB path in AM. The study is limited to numerical simulations, and future work will include extensive experimental validation to verify the proposed optimized LB path designs. The current study provides (via thermo-mechanical analysis) evidence of improvement in terms of deformation minimization for the considered part (metal plate). Originality/value – The proposed LB path optimization framework provides a systematic and automated approach to optimizing the LBAM process. The efficacy of the proposed method is demonstrated by a thermo-mechanical simulation case study where a decrease in the final workpiece deformation is achieved. The simulations aim to identify LB paths that represent optimized solutions concerning the defined fitness criteria. The thermo-mechanical approach and the mechanism behind the reduced deformation are also discussed in detail.

• Language: English
• Keywords: additive manufacturing, laser beam paths, optimization, genetic algorithms, FEM thermo-mechanical simulation, workpiece deformation
• Work type: Article
• Typology: 1.01 - Original Scientific Article
• Organization: FS - Faculty of Mechanical Engineering
• Publication status: Published
• Publication version: Version of Record
• Year: 2026
• Number of pages: Str. 2832-2845
• Numbering: Vol. 43, no. 7
• PID: 20.500.12556/RUL-184708
• UDC: 621.791.72:004.942
• ISSN on article: 0264-4401
• DOI: 10.1108/EC-09-2024-0886
• COBISS.SI-ID: 251005699
• Publication date in RUL: 14.07.2026

Record is a part of a journal

• Title: Engineering computations
• Shortened title: Eng. comput.
• Publisher: Emerald
• ISSN: 0264-4401
• COBISS.SI-ID: 25396480

Licences

• License: CC BY 4.0, Creative Commons Attribution 4.0 International
• Link: http://creativecommons.org/licenses/by/4.0/
• Description: This is the standard Creative Commons license that gives others maximum freedom to do what they want with the work as long as they credit the author.

Secondary language

• Language: Slovenian
• Keywords: aditivna proizvodnja, poti laserskega žarka, optimizacija, genetski algoritmi, MKE termomehanska simulacija, deformacija obdelovanca

Projects

• Funder: ARIS - Slovenian Research and Innovation Agency
• Project number: P2-0241
• Name: Sinergetika kompleksnih sistemov in procesov