Accuracy of complex internal channels produced by laser powder bed fusion process

Abstract Additive manufacturing (AM) technology has great potential in manufacturing complex internal channels for several applications such as satellite-communication microwave systems. These systems can have complex shapes and make traditional finishing processes a challenge for additive parts. Therefore, it is desirable that the internal surfaces are as close as possible to the tolerance of the field of application. In this study, a complex component, a unique waveguide device with bending, twisting and filtering functionalities, has been designed and manufactured in AlSi10Mg alloy through laser powder bed fusion (L-PBF) process. Three different prototypes with three different curvature (R of 50 mm, 40 mm and 30 mm), operating in Ku/K band, have been manufactured and tested showing a very good agreement with the desired performances. Using 3D scan data, the internal deviations from the CAD model have been evaluated showing an average deviation of the internal areas of about 0.08 mm, 0.046 mm and 0.023 mm from the CAD model for the R of 50 mm, 40 mm and 30 mm respectively The surface roughness measured in the internal channel is about Ra (arithmetic average roughness) of 8 μm ± 1.3 μm and Rz (average maximum height of the roughness profile) of 62.3 μm ± 0.34 μm.