Are density cubes sufficient to measure process performance and quality of geometrically complex parts in laser powder bed fusion?

Abstract As additive manufacturing (AM) progresses towards industrialisation with the batch production of complex and critical components, ensuring build quality becomes a significant challenge. Standard benchmarks, such as bulk cubes, may not accurately represent actual performance because of the variability associated with intricate geometries, especially in metal AM technology. This study evaluates the effectiveness of using bulk cubes as quality indicators in Laser Powder Bed Fusion (LPBF) by comparing the density characteristics of bulk cubes to those of complex geometries. Using Ti-6Al-4 V, three batches of 12 Y-tubes, 12 modified cuboids, and 12 bulk cubes were produced and analysed. Density was assessed through the Archimedes method and X-ray computed tomography (XCT). Results revealed significant differences between bulk cubes and more intricate geometries, with correlation analyses indicating weak relationships in density distributions. The XCT results emphasised the importance of geometry-driven porosity patterns, highlighting the limitations of using bulk cubes as standard benchmark parts for assessing part quality. This study demonstrates that geometry is crucial when evaluating quality in metal LPBF processes and promotes the creation of geometry-specific benchmark parts for quality analysis. These findings improve quality control practices and contribute to more reliable process validation in metal additive manufacturing technology.