Abstract
This paper presents the development and experimental validation of a digital twin for a selective laser melting (SLM) system designed for operation under constrained technical conditions. The proposed design includes a custom-built powder feeding and leveling mechanism, along with a telemetry module enabling realtime acquisition and analysis of thermal data. The digital twin is implemented as an integrated model that combines thermomechanical analysis, G-code execution, and corrective control of printing parameters. The mathematical foundation is based on the transient heat conduction equation with a volumetric heat source and a Gaussian distribution of laser power density.An experimental setup employing pyrometers and thermocouples in the melt zone was used to validate the model. The comparison of simulated and measured data showed a mean absolute error of less than 2.5 °C. The application of the digital twin resulted in a 12–15% reduction in residual stresses, as confirmed by X-ray diffraction analysis. The developed system demonstrates high efficiency in predictive quality control and can be integrated into adaptive control loops. The approach aligns with the Industry 4.0 concept, offering increased stability, repeatability, and reliability in SLM processes