Analysing the Impact of Shape Complexity on Mechanical Performance in Additive Manufacturing: Investigation on Aluminium Alloy and Polymer Specimens
Year: 2026
Type: article
Abstract: Laser-Powder Bed Fusion process is one of the most widespread Additive Manufacturing processes for metal and polymeric parts, enabling the realisation of complex, free-form, and low-density structures that are impossible or difficult to realise with traditional manufacturing techniques. However, this process is characterised by defects such as porosity, roughness, layer delamination, and others that limit mechanical behaviour. This work aims to analyse the correlation between mechanical performance and shape complexity in additive manufacturing parts. A complexity index was adopted to characterise the geometry of specimens and lattice structures, and prototyping and testing activities were carried out to evaluate the correlation between the shape complexity and performance. The materials involved in the experimental analysis are Al-Si-Mg, Al-Cu, and PA12, all realised by Laser-Powder Bed Fusion processes. To extend the approach, specimens with a biocompatible resin realised by VAT photopolymerization were also considered. The results show a dependence between shape complexity and mechanical performance, highlighting a non-linear behaviour. Despite the shape complexity offering a significant advantage in achieving tailored component performance in mechanical products, the results showed that designers must use it with particular attention due to fluctuating material performance as shape complexity increases.
Source: Applied Sciences
DOI: 10.3390/app162110612
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $2,896
Funder: Royal Society
OpenAlex ID: W7212296510