Evaluation of Selected Quality Characteristics of Thin-Walled Models Manufactured Using Powder Bed Fusion Technology

This publication presents the results of research on selected quality features of sample models made using 3D printing technology from the Powder Bed Fusion (PBF) group and a material based on aluminum powder. Two quality areas were analyzed: tensile strength and geometric surface structure. Strength tests of thin-walled models were carried out for samples with four given thicknesses of 1, 1.4, 1.8, and 2 mm and four printing directions, namely, three in the XZ plane and one in the XY plane. The measurement of the geometric structure was carried out using optical measuring devices and by taking into account the assessment of roughness and waviness parameters. Using scanning electron microscopy (SEM), an analysis of the fracture of samples after rupture was carried out and the surface was assessed for technological defects created in the manufacturing process. The test results showed that for thin-walled sample models, there are certain technological limitations regarding the minimum sample thickness in the manufacturing process and that the strength of thin-walled models in relation to "solid" samples depends on both the sample thickness and the printing direction. Roughness parameters that determine functional quality characteristics such as friction and wear were determined and also showed a dependence on the printing direction.