Process capability analysis of additive manufacturing process: a machine learning−based predictive model

Purpose: Predicting dimensional and geometrical errors in 3D printing parts during the design stage can significantly enhance the product’s quality. This study aims to predict the form deviation and process capability in additive manufacturing (AM) specimens considering layer thickness, laser power and scan speed parameters in the laser powder bed fusion (LPBF) method. Various machine learning (ML) techniques are implemented to estimate the form deviation and process capability with the highest accuracy in 3D-printed cylindrical parts as a case study. Design/methodology/approach: The workflow started by simulating the LPBF AM process using a finite element modeling approach. Then, different ML algorithms like artificial neural networks are used to predict the form deviation. The process capability value is forecasted using some classification ML models and process capability indices (PCIs) for cylindrical parts. Finally, concentricity tolerance classification is performed for cylindrical parts, which can ensure quality control issues in the production stage. Findings: Results present an accuracy of about 93% for predicting form deviations and 95% accuracy for predicting PCI C_pm in PCI classification based on random forest model as an ML algorithm. Originality/value: The noteworthy point of the research is accessing the form deviation due to AM and process capability evaluation in the AM process before the production stage, which has not been studied before based on the author’s knowledge. So that the product quality is evaluated based on the shape deviation and its tolerances in the AM process digital chain. © 2024, Emerald Publishing Limited.