Numerical modelling of laser rapid prototyping by fusion wire deposit

A finite element model has been developed to simulate an innovative laser rapid prototyping process. Several numerical developments have been implemented in order to simulate the main steps of the rapid prototyping process: injection, heating, phase change and deposit. The numerical model also takes into account different phenomena: surface tension in the liquid state, asborptivity and plasma effects during materiallaser interaction. The threedimensional model is based on the lagrangian approach used in the Forge® finite element software. The thermal model coupled with materiallaser model is compared and gives good agreements. Simulations of the rapid prototyping are compared with experimental results.