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Additive manufacturing by laser powder bed fusion (LPBF) requires process parameters that consider both local and global thermal gradients to address material and component quality issues caused by non-uniform heating and cooling. Here, we develop an analogy between natural predator-prey behaviour and heat flow in LPBF, and consequently derive a spiral pattern that is translated into a discrete vector pattern compatible with LPBF. A power optimisation routine is applied to the spiral pattern to maintain constant melt pool depth, and the simulated thermal histories are compared to well-established zig-zag and helix scan patterns. From these results, we propose that the spiral pattern reduces the spatial variation of temperature, while a larger area remains above a specified threshold temperature at the end of the scan. Consequently, the spiral pattern may be promising for printing crack-prone materials, and for parameter optimisation of LPBF overall, and should be experimentally validated in future work.

A spiral laser scanning routine for powder bed fusion inspired by natural predator-prey behaviour