Melting Cell Based Compensated Design Method for Improving Dimensional Accuracy of Additively Manufactured Thin Channels

Abstract Powder-bed fusion additive manufacturing technology makes it possible to produce parts with complicated geometry and high accuracy. However, dimensional deviation caused by powder overmelting dross formation is still a challenge for thin channels. In this study, the origins of printed channels were analyzed concept called “melting cell” proposed describe quantify geometric error. Based on geometrical relationship between melting cell target channel, method predicting optimizing final outlined. order verify method, geometries horizontal circular in various sizes are studied as examples. The predicted results show remarkable agreement available experimental results. Moreover, new egg-shaped compensated design, which able improve accuracy channels, presented. simple yet very effective. It can be easily extended shapes, materials, different bed processes.