In metal additive manufacturing, enclosed cavities can pose a significant challenge if not carefully designed. One of the most overlooked but critical aspects is powder removal. When cavities are closed or poorly ventilated, unmelted powder becomes trapped inside during the build process. This not only increases the part's overall weight but also introduces a risk for hidden defects and internal weaknesses that compromise functionality.
To address this, engineers should strategically incorporate escape holes that allow for the effective removal of residual powder. These holes must be appropriately sized and placed to ensure they facilitate powder drainage without weakening structural integrity. This is especially vital in designs with internal channels, lattice structures, or other complex geometries that would otherwise retain material. Efficient powder evacuation not only simplifies post-processing but also enhances the cleanliness of internal features and improves the reliability of the final product.
Well-placed escape holes reflect a balance between manufacturability and performance. In high-precision industries like aerospace or automotive, ensuring clean internals can be the difference between success and a critical failure. Taking a proactive approach in the CAD stage to identify potential powder traps is a best practice that every design team should implement.