A review of geometric sensitivities in laser metal 3D printing

ABSTRACT

This paper examines the relationships in laser metal additive manufacturing between part geometry and as-built part quality, including residual stresses, deformations, process induced porosity, surface roughness, and microstructural variations. A comprehensive review of these defects and their relationships with the geometric features are provided along with a brief discussion of the involved physical phenomena. Specific design guidelines are also provided to facilitate a more robust design for structural applications. This review further highlights the need to pursue the development of design methodologies, including automated topology, shape, and sizing optimisation methods, that help derives an optimal design tailored for these process-induced quality considerations in laser metal additive manufacturing that affect structural performance.

KEYWORDS:

• Geometric sensitivities
• design guidelines
• selective laser melting
• additive manufacturing

Disclosure statement

No potential conflict of interest was reported by the authors.

Notes on contributors

Vedant Chahal is a Ph.D. student in the Department of Mechanical and Aerospace Engineering at The University of Texas at Arlington, Arlington, Texas, USA. His research focuses on process-induced defects in laser metal 3D printing and characterising the involved geometric sensitivities to tailor design optimisation techniques and consequently improve the structural performance.

Robert M. Taylor is a Professor in Practice in Mechanical and Aerospace Engineering at The University of Texas at Arlington where he teaches university classes in classical and computational structural mechanics, design, and manufacturing. His research efforts focus on structural optimisation with an emphasis on design for additive manufacturing. He previously worked as a practicing aerospace structural engineer on military and general aviation aircraft. He received his Ph.D. and M.S. from Purdue University and a B.S. from Brigham Young University.