Full-surface geometric analysis of DMLS-manufactured stainless steel parts after post-processing treatments

Szabó, Valentin Endre and Weltsch, Zoltán (2025) Full-surface geometric analysis of DMLS-manufactured stainless steel parts after post-processing treatments. RESULTS IN ENGINEERING, 27. No. 106084. ISSN 2590-1230

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Abstract

The study examines the geometric behavior of corrosion-resistant steel components manufactured using the DMLS (Direct Metal Laser Sintering) process after various post-treatment methods. Full-surface 3D optical scanning was used to evaluate geometric deviations before and after three different treatments: stress relief heat treatment, immediate base plate removal, and natural aging. The results showed that heat treatment amplified the distortions caused by existing residual stresses, with elliptical deformation nearly doubling (i.e., deteriorating by approximately 200 %). Immediate removal resulted in asymmetrical, teardrop-shaped distortion that exceeded the ±0.1 mm tolerance limit. Natural aging effectively stabilized the geometry, with circularity deviation remaining within the ±0.1 mm limit. The results highlight the critical role of thermal management and post-processing in ensuring the dimensional accuracy of DMLS parts. The research demonstrates the advantages of full-surface, high-precision optical metrology in the detailed analysis of shape changes occurring during additive manufacturing, with the maximum permissible error of the measuring system limited to 0.01 mm in our measurements.

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