Conference Agenda

Residual stress is inherent in Additive Manufacturing process due to the heat cycling of the material being deposited on the build plate. The manufacturing toolpath can have a considerable effect on the development of residual stress distribution within a component. This paper examines the impact of the shell feature to generate some design heuristics on whether to include it when residual stress is of concern. The stress feature did increase the residual stressed observed during printing but was mitigated by the cooling regime after the process was complete.

We present a geometry-based complexity factor for additive manufacturing that estimates relative printing effort of fused filament fabricated parts from STL geometry alone. A reference effort is derived by slicing thousands of parts and volume-equivalent cubes. Eight interpretable geometric metrics feed a constrained, regularised index with monotonic calibration, achieving robust test accuracy and revealing which shape features dominate structural complexity.

Turbine blades are high-value components whose replacement is costly and slow, increasing the demand for effective repair strategies. Although PBF-LB/M supports precise additive repair, its application is limited by manual and time-intensive part preparation. This work introduces an automated digital workflow for cutting plane definition, repair geometry reconstruction and part alignment, improving reproducibility and reducing preparation time in PBF-LB/M-based turbine blade repair.