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<p>To ensure dimensional repeatability of additively manufactured parts, it is crucial to evaluate their dimensional and geometrical properties and to determine the capabilities of these systems to produce certain features. In this sense, the purpose of this research is to understand the influence of the layer thickness on the dimensional and geometrical accuracy of parts produced by powder bed fusion–laser beam. Three builds of a standard test artefact were fabricated in AlSi10Mg with three different layer thicknesses: 0.025&#xa0;mm, 0.050&#xa0;mm, and 0.075&#xa0;mm. Some features including pins, holes, and staircase flats of various sizes were measured using computed tomography and an inspection software. The results showed that relative dimensional errors tend to be higher in smaller features, regardless of the layer thickness. Moreover, in some features, a higher layer thickness provided less dimensional deviations although with superior surface roughness. Regardless of the feature type, the minimum size achieved was 0.5&#xa0;mm, with tolerances in the 5 ≤ IT ≤ 11 range, which applies to parts with mechanical constraints, medium finishing, and potential use in functional parts. Based on these findings, this research showed that it is possible to save around 60% of the build time for AlSi10Mg parts, depending on the dimensional, geometrical, and surface roughness requirements for each application.</p>

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Influence of layer thickness on dimensional and geometrical properties of aluminium parts produced by powder bed fusion

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年6月2日

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  • Eva C. Silva,
  • Ana C. Lopes,
  • Álvaro M. Sampaio,
  • António J. Pontes

摘要

To ensure dimensional repeatability of additively manufactured parts, it is crucial to evaluate their dimensional and geometrical properties and to determine the capabilities of these systems to produce certain features. In this sense, the purpose of this research is to understand the influence of the layer thickness on the dimensional and geometrical accuracy of parts produced by powder bed fusion–laser beam. Three builds of a standard test artefact were fabricated in AlSi10Mg with three different layer thicknesses: 0.025 mm, 0.050 mm, and 0.075 mm. Some features including pins, holes, and staircase flats of various sizes were measured using computed tomography and an inspection software. The results showed that relative dimensional errors tend to be higher in smaller features, regardless of the layer thickness. Moreover, in some features, a higher layer thickness provided less dimensional deviations although with superior surface roughness. Regardless of the feature type, the minimum size achieved was 0.5 mm, with tolerances in the 5 ≤ IT ≤ 11 range, which applies to parts with mechanical constraints, medium finishing, and potential use in functional parts. Based on these findings, this research showed that it is possible to save around 60% of the build time for AlSi10Mg parts, depending on the dimensional, geometrical, and surface roughness requirements for each application.