Iterative Learning Control of the Cooling Rate in a Dual-Laser Powder Bed Fusion Process

The thermal history of the melt pool in laser powder bed fusion (LPBF) additive manufacturing processes governs the solidification microstructure and the mechanical properties of the resulting 3D-printed parts. Dual-laser systems offer additional degrees of freedom to control the cooling profile by reheating material behind the melt pool, but calibrating process parameters is challenging due to the complex physics of the process. We present an optimization-based iterative learning controller that determines optimal power, velocity, and offset settings by judiciously combining simulations and experiments: the model supplies search directions while feedback obtained from experiments on the real plant corrects for parameter errors, enabling convergence despite model inaccuracies. The approach is validated in simulation using a high-fidelity thermal model as a plant surrogate, with deliberate mismatches in absorption coefficient, latent heat treatment, and powder-bed effective conductivity between plant and model. Results show that the controller drives the plant cost down by over an order of magnitude and reaches a tight band of low-cost solutions across seeds, while model-only feedforward optimization stalls at a substantially higher plant cost despite appearing to converge on the surrogate.