In this paper, the deposition layer calculation model is proposed for laser-directed energy deposition (DED) with coaxial powder feeding by combining the powder feeding equation with the volume of fluid (VOF) method, and the single-channel IN718 forming process is simulated in real-time with moving boundary conditions in a fixed coordinate system and experimentally validated. Under single-layer single-channel deposition processing, the deposition height and width decreased by 57.1% and 21.6%, respectively, as the scanning speed increased from 8 mm/s to 14 mm/s. The calculated deposition height, width, and melt pool depth were in good agreement with the experimental results. Calculating the temperature field distribution of the single-layer double-channel deposition at an overlapping-rate of 30% yielded the temperature fluctuation pattern of the deposition at various lap moments. Under the influence of the thermal accumulation of the first deposition channel, the latent heat effect of the melt pool will cause the maximum surface temperature during overlap processing to be slightly lower than the maximum surface temperature during single channel processing; at the same time, under the influence of the high-temperature state of the overlap deposition channel during the scanning process, the first deposition channel will exhibit rewarming during the overlap scanning process. The deposition layer and temperature field of single-layer multi-channel laser deposition are modelled using this information. It has been proved that the model may be used to forecast deposition and temperature fields for intricate processing procedures. The study findings are significant for understanding the process mechanism of coaxial powder feeding laser-directed energy deposition in detail and optimizing the process.

The spread and penetration of binder droplets have a significant impact on the dimensional accuracy and strength of the parts. In this paper, a three-dimensional numerical simulation method for studying the spread and penetration of multiple micron droplets in porous media is proposed and verified by experiments. The results show that the spreading diameter and penetration depth of the binder increase with the number of droplets. However, as the number of droplets increases, the magnitude of their increase decreases. The research results can be used to predict the true spread and penetration state in the Droplet-Powder system and provide help for further understanding the inherent mechanism of photocuring binder spray material increment manufacturing.

The penetrating behavior of binder droplets has a substantial effect on the dimensional correctness and strength of the manufactured components. In this article, a physical model and a mathematical model of multiphase flow are created, computationally computed, and experimentally validated to predict the spreading and penetration behavior of multi‐drop binder in a powder bed. The findings indicate: 1) The spreading diameter and penetration depth of the binder increase as the number of droplets grows. However, the size of the rise reduces as the number of droplets grows. 2) The binder is spread symmetrically in the powder bed, with greater saturation in the middle area than margins on both sides, and a higher saturation in the upper region than the lower. 3) Repeated drops of binder in various areas may improve the saturation of the peripheral region while ensuring that the core area is not oversaturated. 4) It is discovered that as the number of ink jet drops rises, the size of the sample grows, and the growth in sample size reduces with the number of ink jet drops. This paper's findings provide light on the mechanics behind light‐cured binder jet additive manufacturing.