Purpose The purpose of this paper is to describe the use of a test artifact proposed by NIST to quantify the dimensional accuracy of a metal additive manufacturing process. Insights from this paper are given concerning both the performance of the machine, a concept laser Mlab cusing machine, and the applicability of the NIST test artifact in characterizing accuracy. Recommendations are given for improving the artifact and standardizing a process for evaluating dimensional accuracy across the additive manufacturing industry. Design/methodology/approach Three builds of the NIST additive manufacturing test artifact were fabricated in 316 stainless steel on a concept laser Mlab cusing machine. The paper follows the procedure described by NIST for characterizing dimensional accuracy of the additive process. Features including pins, holes and staircase flats of various sizes were measured using an optical measurement system, a touch probe and a profilometer. Findings This paper describes the accuracy of printed features’ size and position on the test artifact, as well as surface finish on flat and inclined surfaces. Trends in variation of these dimensions are identified, along with possible root causes and remedies. This paper also describes several strengths and weaknesses in the design of the test artifact and the proposed measurement strategy, with recommendations on how to improve and standardize the process. Originality/value This paper reviews a previously proposed design and process for measuring the capabilities of additive manufacturing processes. It also suggests improvements that can be incorporated into future designs and standardized across the industry.

Metal powder bed fusion (PBF) additive manufacturing (AM) builds metal parts layer by layer upon a substrate material. The strength of this interface between the substrate and the printed material is important to characterize, especially in applications where the substrate is retained and included in the finished part. Ensuring that this interface between the original and the printed material has adequate material properties enables the use of this PBF AM process to repair existing structures and create new parts using both AM and conventional manufacturing. This paper studies the tensile and torsional shear strengths of wrought and PBF-built SS316L specimens and compares them to specimens that are composed of half wrought material and half PBF material. These specimens were created by building new material via PBF onto existing wrought SS316L blocks, then cutting the specimens to include both materials. The specimens are also examined using optical microscopy and electron backscatter diffraction (EBSD). The PBF specimens consistently exhibited higher strength and lower ductility than the wrought specimens. The hybrid PBF/wrought specimens performed similarly to the wrought material. In none of the specimens did any failure appear to occur at or near the interface between the wrought substrate and the PBF material. In addition, most of the deformation in the PBF/wrought specimens appeared to be limited to the wrought portion of the specimens. These results are consistent with optical microscopy and EBSD showing smaller grain size in the PBF material, which correlates to increased strength in SS316L due to the Hall–Petch relationship. With the strength at the interface meeting or exceeding the strength of the original wrought material, this process shows great promise as a method for adding additional features or repairing existing structures using metal PBF AM.

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Metal powder bed fusion (PBF) additive manufacturing (AM) builds metal parts layer by layer upon a substrate material. The strength of this interface between substrate and printed material is important to characterize, especially in applications where the substrate is retained and included in the finished part. This paper studied the tensile and torsional strengths of wrought and additively manufactured (through PBF) SS316L and compared them to specimens composed of half wrought material and half PBF material. The PBF specimens consistently exhibited higher strength and lower ductility than the wrought specimens. The hybrid PBF/wrought specimens performed similarly to the wrought material. In no specimens did any failure appear to occur at or near the interface between wrought substrate and PBF material. In addition, most of the deformation in the PBF/wrought specimens appeared to be limited to the wrought portion of the specimens. These results are consistent with microscopy showing smaller grain size in the PBF material, which often leads to increased strength in SS316L due to the Hall-Petch relationship.

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