Quantifying Thermal Model Accuracy in PBF-LB/M using Statistical Similarity Tests Against Thermographic Measurements

Quantifying Thermal Model Accuracy in PBF-LB/M using Statistical Similarity Tests Against Thermographic Measurements | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Quantifying Thermal Model Accuracy in PBF-LB/M using Statistical Similarity Tests Against Thermographic Measurements Vijaya Holla, Brandon Lane, Jesse Redford, Philipp Kopp, Stefan Kollmannsberger This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7536866/v2 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 12 Dec, 2025 Read the published version in Integrating Materials and Manufacturing Innovation → Version 2 posted You are reading this latest preprint version Show more versions Abstract Numerical simulation models for Laser Powder Bed Fusion of metals (PBF-LB/M) vary in complexity and fidelity, ranging from high-fidelity models that capture melt pool dynamics to simplified models suited for part-scale temperature predictions and process optimizations. Validation against experimental data is essential to build confidence in their predictive capabilities. However, for in-situ thermographic measurements, a direct comparison is challenging due to the data’s size and the multi-scale nature of the process. Similarities must be analyzed at different spatial and temporal scales based on the model’s fidelity and its intended application. For example, agreement between a thermal simulation and measurement in a steady-state scenario does not guarantee accuracy during transient phases. Statistical similarity measures provide a quantitative means to assess model-measurement agreement, highlighting regions of high and low similarity. In this work, we validate a thermal simulation model, discretized using the space-time finite element method, against thermographic camera measurements using various similarity metrics and evaluate their applicability to PBF-LB/M. We also propose a multi-scale similarity assessment approach tailored to model fidelity and application. Thermal simulation Model-Measurement comparison Similarity Tests Space-Time Finite Element Method Thermography Full Text Additional Declarations The authors declare no competing interests. Cite Share Download PDF Status: Published Journal Publication published 12 Dec, 2025 Read the published version in Integrating Materials and Manufacturing Innovation → Version 2 posted You are reading this latest preprint version Show more versions Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7536866","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[{"code":1,"date":"2025-09-05 07:27:07","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research 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simulation models for Laser Powder Bed Fusion of metals (PBF-LB/M) vary in complexity and fidelity, ranging from high-fidelity models that capture melt pool dynamics to simplified models suited for part-scale temperature predictions and process optimizations. 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