A Robust Design Perspective on Factors Influencing Geometric Quality in Metal Additive Manufacturing

Abstract

Abstract Additive manufacturing (AM) for metals is a widely researched, continuously enhanced manufacturing process and is implemented across various industries. However, the AM process exhibits variation that affects the geometric quality of the end product. The effect of process variation on geometric quality is rarely considered during the design stages. In this paper, sources that influence the geometric quality in a metal AM process are reviewed from a robust design perspective and further sorted into control factors and noise factors. A framework for geometric robustness analysis of AM products is presented as an outcome. This framework would facilitate development of methods and tools to produce geometry assured AM products. Also, the prospects of variation simulation to support geometric robustness analysis and the challenges associated with it are discussed.