In additive manufacturing, controlling dimensional accuracy during the build process is critical, especially in high-performance applications where tolerances are tight and reliability is non-negotiable. One often overlooked factor influencing this accuracy is thermal expansion. Certain high-performance alloys used in selective laser melting (SLM) exhibit less than 0.1% expansion throughout the printing process. This ultra-low expansion means parts retain their shape and dimensions with exceptional fidelity, even under thermal stress.
This characteristic becomes vital in industries like aerospace, energy, and medical implants, where precision is paramount. A minor deviation in geometry can cascade into mechanical inefficiencies or failure. By choosing alloys with stable thermal behavior, engineers can reduce post-processing time and the need for extensive dimensional corrections. That translates into faster turnaround and lower costs.
Additionally, minimized thermal distortion significantly reduces internal stress accumulation during the print. This makes parts less prone to warping or cracking, improving both the short-term manufacturability and long-term performance of the part in service. Parts behave predictably across thermal cycles, improving design confidence.
Ultimately, dimensional stability in AM isn’t just about meeting tolerance, it’s about ensuring function under pressure. As more sectors adopt additive manufacturing for mission-critical parts, selecting materials with minimal thermal expansion is key to unlocking the full performance potential of printed components.