Dimensional accuracy of fabricated geometries through powder bed fusion: An overview and a new benchmark artifact proposal
Erfan Maleki, Behnam Salehnasab, Mikyle Paul, Shuai Shao, Nima Shamsaei
Abstract
Dimensional accuracy of fabricated parts by powder bed fusion (PBF) is a critical parameter that directly affects the quality, reliability, and performance of the product. As the number of PBF machines and processes continues to increase, there is an emerging need for efficient tools and techniques to evaluate their attributes with respect to dimensional accuracy. Benchmark artifacts with geometries particularly designed to interrogate and challenge the capabilities of PBF equipment may provide a practical foundation for cross-platform comparative research. Through comparison to artifacts, researchers and manufacturers can extensively study the capabilities and limitations of several manufacturing technologies on an equal basis in controlled environments. This approach facilitates informed decision-making regarding technology selection for specific applications and industries. This overview consolidates the current knowledge, offering insights into factors influencing the dimensional accuracy of fabricated parts, effective assessment methodologies, and emphasizing key criteria for artifact design. Different artifact geometries are explored, each representing a key feature in PBF parts susceptible to dimensional deviations, along with their roles in assessing PBF systems’ performance. In addition, the need to incorporate diverse geometries in the same build plate is discussed. Based on the state of the art reviewed and knowledge gaps identified, a novel comprehensive build plate is proposed.