One of the most persistent misconceptions in metal additive manufacturing is that thermal management only matters for large parts. In reality, small geometries can be even more vulnerable to thermal distortion. Their limited mass means heat cannot dissipate as gradually, causing steep temperature gradients and localized residual stresses. These stresses accumulate quickly and often remain hidden until the part is removed from the build plate or enters service.
During laser powder bed fusion, every melt pool introduces thermal expansion followed by rapid cooling and contraction. In small parts, this cycle happens repeatedly in a confined region, making it easier for heat to concentrate in hot spots. Without proper thermal strategies, this can result in subtle warping, dimensional drift, or layer separation, even in parts that appear simple.
Thermal control strategies such as optimized scan patterns, build plate preheating, and adjusted layer timing are critical for managing heat distribution. Alternating scan directions, segmenting scan islands, or spacing laser exposure across the layer helps prevent heat buildup. These techniques ensure that even tiny geometries experience balanced cooling and consistent solidification.
Ultimately, thermal management is not about part size, it’s about thermal behavior. Small parts demand the same level of process planning as large ones to ensure repeatability and dimensional accuracy. Ignoring this can lead to costly reprints, extended post-processing, and reduced reliability.