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Reverse Engineering and Dimensional Limits Analysis of Samples Fabricated Using Selective Laser Melting Process

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Abstract

Selective laser melting (SLM) is a powder-based process that has gained massive attention due to excellent design flexibility and complex part fabrication with a microscopic resolution. This study focused on the dimensional accuracy analysis of SLM-manufactured parts using 3D scanning technology. The primary objective is to provide a system that integrates the reverse engineering concept with additive manufacturing (AM) design principles. 316L stainless steel (SS) samples are scanned using an EinScan Pro 3D scanner, and the precise details of geometric attributes, such as full length, gauge length, diameter, and thickness, were gathered. Three-dimensional scanning captures many surface data points to produce a more accurate object representation. The gathered information was correlated with the American Society for Testing and Materials (ASTM) E-466 standard. The dimensional stability of parts was investigated to correlate with process parameters. The dimensional error of fabricated part’s is investigated at different orientations; every axis and the respective dimensional variations are shown in detail. Analysis of variance (ANOVA) was done to obtain the significant parameter for dimensional stability. It showed that the minimum dimensional stability of the parts was obtained at a high laser power of 300 W, a high scanning speed of 1100 mm/s, and a low hatch distance of 80 μm, corresponding to an energy density of 56.81 J/mm3. Scanning speed significantly affects the dimensional accuracy of SLM fabricated parts.

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Authors and Affiliations

  1. Department of Mechanical Engineering, National Institute of Technology Delhi, Delhi, 110036, India

    Meena Pant, Leeladhar Nagdeve & Harish Kumar

  2. CSIR-National Physical Laboratory, New Delhi, 110012, India

    Girija Moona

  3. Academy of Scientific and Innovative Research (AcSIR), CSIR-HRDC Campus, Ghaziabad, 201002, India

    Girija Moona

  4. School of Automation Banasthali Vidyapith, RadhaKishnpura, Rajasthan, 304022, India

    Parth Patpatiya

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  1. Meena Pant
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  2. Parth Patpatiya
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  3. Leeladhar Nagdeve
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  4. Girija Moona
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  5. Harish Kumar
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Correspondence to Harish Kumar.

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Pant, M., Patpatiya, P., Nagdeve, L. et al. Reverse Engineering and Dimensional Limits Analysis of Samples Fabricated Using Selective Laser Melting Process. MAPAN 38, 795–804 (2023). https://doi.org/10.1007/s12647-023-00639-9

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  • DOI: https://doi.org/10.1007/s12647-023-00639-9

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