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For the First Time, it is Known in Advance Where a 3D Printed Part Needs Post-Processing

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The results from the model experiments revealed, as stated, an increase in fatigue strength of up to 40%! Additionally, there was an extension of the service life by several decades, as emphasized by the IWM researchers. The calculation results were then experimentally validated through fatigue tests at both sample and component levels (see header image). With this new method, the IWM researchers are now opening up opportunities for new applications. It can already be used in early development, enabling a computational comparison of different post-treatment strategies before the first component test takes place. Another advantage is that components mostly fail starting from the surface! Therefore, a tailored post-treatment can partially compensate for process-related variations in the printing process. Based on fundamental material properties such as yield strength and tensile strength, the effects can also be transferred to new materials, according to the experts. For the first time, a computational design tool for the mechanical surface post-treatment of additively manufactured metal components is now available.

(The project results were developed as part of the project "Mechanical surface post-processing of additively manufactured metallic components for targeted improvement of fatigue strength" (funding code IGF 22833 N, AM Surface) funded by the Federal Ministry for Economic Affairs and Energy (BMWi) and were subsequently expanded and enhanced.)

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