Metal AM Process Informatics for Improved Surface Finish of Complex Parts

Metal additive manufacturing (AM) creates complex 3D components at near net shape. Surface finish(SF) of the

AM part is uneven, with surface roughness being variable over the facets of the design. The surface quality

achievable using standard post-processing methods is unacceptable for some industry sector AM part uptake.

The challenge here is to improve metal AM part surface finish by decreasing the variability of surface roughness

of the near net-part during AM production and to improve post-processing (PP) techniques to suit increased

AM part complexity. This project aims to develop an innovative process optimisation system which can link AM

build parameters to the surface finish produced to generate a software tool for AM designers to use to select

the best parameters to generate an optimised surface finish for the individual AM part, and subsequent

optimised post-processing SF methodologies. This approach will optimise both the AM build process as well as

PP techniques to enable the delivery of the required surface finishes, increase industrial adoption of high-value

AM parts, generating increased sales and employment while supporting UK manufacturing innovation.