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Numerical simulations of a complete laser powder bed fusion (LPBF) additivemanufacturing (AM) process are extremely challenging or even impossible toachieve without a radical model reduction of the complex physical phenomenaoccurring during the process. However, even when we adopt reduced model withsimplified physics, the complex geometries of parts usually produced by LPBF AMprocesses make this kind of analysis computationally expensive. In fact, smallgeometrical features - which might be generated when the part is designfollowing the principal of the so-called design for AM, for instance, by meansof topology optimization procedures - often require complex conformal meshes.Immersed boundary methods seem to offer a valid alternative to deal with thiskind of complexity. The two-level method lies within this family of numericalmethods and presents a very flexible tool to deal with multi-scale problems. Inthis contribution, we apply the recently introduced two-level method topart-scale thermal analysis of LPBF manufactured components, first validatingthe proposed part-scale model with respect to experimental measurements fromthe literature and then applying the presented numerical framework to simulatea complete LPBF process of a topologically optimized structure, showing thecapability of the method to easily deal with complex geometrical features.

Two-level Method Part-scale Thermal Analysis of Laser Powder Bed Fusion Additive Manufacturing