Brenner, S. & Nedeljkovic Groha, V. (2025). Improving Vertical Dimensional Accuracy in PBF-LB/M Through Artefact-Based Evaluation and Correction. Applied Sciences.
Abstract
Achieving high dimensional accuracy in the build direction remains a critical challenge in
laser-based powder bed fusion of metals (PBF-LB/M), particularly for taller components.
This study investigates the application of the standardized Z-artefact defined in ISO/ASTM
52902:2023 to evaluate and correct vertical dimensional deviations in AlSi10Mg parts.
Benchmark artefacts were produced without Z-scaling and measured using a structured
light 3D scanner. A linear trend of increasing undersizing with build height was observed
across two build jobs, indicating a systematic Z-error. Based on the reproducible average
deviation, a shrinkage compensation factor of 1.0017 was derived and applied in a third
build job using the same processing parameters. This correction reduced the root mean
square error (RMSE) from over 100 μm to below 25 μm and improved the achievable ISO
tolerance grades from IT 9–11 to IT 5–9. The approach proved effective without requiring
changes to process parameters. However, local surface features such as elevated edges
and roughness remained dominant sources of deviation and are not captured in step
height-based evaluations. Overall, this study demonstrates a practical, standard-compliant
method to improve vertical dimensional accuracy in PBF-LB/M, with potential applicability
to industrial quality assurance and future extension to more complex geometries