The accuracy of parts manufactured using Selective Laser Sintering (SLS) is significantly influenced by various technological and process parameters. This study presents a comprehensive error prediction model for analyzing and forecasting dimensional accuracy in SLS manufacturing. The model incorporates primary error sources including triangulation errors, shrinkage compensation errors, laser beam spot size variations, and powder particle discretization effects. Statistical modeling of the error formation mechanisms revealed that the resulting dimensional accuracy is predominantly affected by shrinkage compensation errors, which can reach up to 0.06 mm in industrial conditions. The research established that significant improvement in dimensional accuracy (up to 90%) can be achieved by reducing three primary error sources: shrinkage compensation settings, laser beam spot size variation, and Z-axis layer thickness compensation. The developed model enables the prediction of resulting dimensional errors based on 26 input parameters grouped into triangulation model parameters, build project parameters, and manufacturing parameters. The study's findings provide valuable insights for optimizing SLS process parameters and achieving higher dimensional accuracy. The model demonstrates that the achievable manufacturing accuracy is approximately 20 times better than the resulting error under current technological limitations. This research contributes to the understanding of error formation mechanisms in SLS and provides a practical tool for predicting and minimizing dimensional inaccuracies in manufactured parts.

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Error Prediction Model for Dimensional Accuracy in Selective Laser Sintering

  • Yaroslav Garashchenko,
  • Predrag Dašić,
  • Yevgeniy Ostroverkh,
  • Andrii Poharskyi,
  • Olena Harashchenko

摘要

The accuracy of parts manufactured using Selective Laser Sintering (SLS) is significantly influenced by various technological and process parameters. This study presents a comprehensive error prediction model for analyzing and forecasting dimensional accuracy in SLS manufacturing. The model incorporates primary error sources including triangulation errors, shrinkage compensation errors, laser beam spot size variations, and powder particle discretization effects. Statistical modeling of the error formation mechanisms revealed that the resulting dimensional accuracy is predominantly affected by shrinkage compensation errors, which can reach up to 0.06 mm in industrial conditions. The research established that significant improvement in dimensional accuracy (up to 90%) can be achieved by reducing three primary error sources: shrinkage compensation settings, laser beam spot size variation, and Z-axis layer thickness compensation. The developed model enables the prediction of resulting dimensional errors based on 26 input parameters grouped into triangulation model parameters, build project parameters, and manufacturing parameters. The study's findings provide valuable insights for optimizing SLS process parameters and achieving higher dimensional accuracy. The model demonstrates that the achievable manufacturing accuracy is approximately 20 times better than the resulting error under current technological limitations. This research contributes to the understanding of error formation mechanisms in SLS and provides a practical tool for predicting and minimizing dimensional inaccuracies in manufactured parts.