Laser Powder Bed Fusion (L-PBF) is an additive manufacturing (AM) technology which has enabled the fabrication of highly complex structures and components. A major challenge in producing these high complexity structures is predicting where defects are likely to occur, and how severe those defects will be. In this study build geometry is linked to manufacturability, using quantifiable AM defects and metrics. This was achieved by fabricating a variety of unsupported, thin-walled samples with different curvatures using Al-10Si-Mg alloy. A combination of X-Ray computed tomographic (XCT) and digital stereomicroscopy were used to capturing positional data about the total geometric error, surface quality and roughness metrics (R_a and R_z). This dataset was used to create empirical model which predicts geometric error based on the local curvature, orientation and thickness of the computer-aided-design (CAD) geometry. Local inclination angle was observed to have the strongest effect on manufacturability, heavily impacting the geometric error and surface quality metrics. Sample shape defined by curvature was observed to be a secondary factor, which became important in areas of low inclination angle. The empirical model was applied in a case study of a cellular structure, the double gyroid, which successfully identified problematic regions of the structure. The approach of linking fundamental geometry features to defects shown in this study provides additional guidance in design for AM, with potential applications in topology optimisation, optimising part orientation to reduce support, and for design of other intricate components such as the internal conduits of heat exchange devices, where supports are not feasible to use.

激光粉末床熔合（L-PBF）是一种增材制造（AM）技术，能够制造高度复杂的结构和组件。产生这些高复杂性结构的主要挑战是预测缺陷可能发生的位置以及这些缺陷的严重程度。在这项研究中，使用可量化的AM缺陷和度量将建筑的几何形状与可制造性联系在一起。这是通过使用Al-10Si-Mg合金制造各种曲率不同的无支撑薄壁样品来实现的。X射线计算机断层扫描（XCT）和数字立体显微镜相结合，用于捕获有关总几何误差，表面质量和粗糙度度量（R _a和R _z）。该数据集用于创建经验模型，该模型基于计算机辅助设计（CAD）几何的局部曲率，方向和厚度来预测几何误差。观察到局部倾斜角对可制造性的影响最大，严重影响了几何误差和表面质量指标。观察到由曲率定义的样品形状是次要因素，这在低倾斜角区域变得很重要。该经验模型被应用于细胞结构双螺线管的案例研究中，该结构成功地确定了该结构的有问题的区域。这项研究中显示的将基本几何特征与缺陷联系起来的方法为AM的设计提供了额外的指导，并在拓扑优化中具有潜在的应用，