Rapid manufacturing is an advanced manufacturing technology based on layer-by-layer manufacturing to produce a part. This paper presents experimental work carried out to investigate the effects of scan speed, layer thickness, and building direction on the following part features: dimensional error, surface roughness, and mechanical properties for DMLS with DS H20 powder and SLM with CL 20 powder (1.4404/AISI 316L). Findings were evaluated using ANOVA analysis. According to the experimental results, build direction has a significant effect on part quality, in terms of dimensional error and surface roughness. For the SLM process, the build direction has no influence on mechanical properties. Results of this research support industry estimating part quality and mechanical properties before the production of parts with additive manufacturing, using iron-based powder

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Selective laser melting (SLM) is an advanced manufacturing technology based on layer by layer building to produce solid parts from metallic powder (Kruth et al., CIRP Ann Manuf Technol 56:730-760, 2007). Commercial SLM machines are configured to use specific parameters to process different metallic powder grades. This paper proposes a methodology that makes it possible to analyze the effect of energy density on the formation of single tracks from CoCrMo powder, using a noncommercial machine to select process parameters with open source technology. Full factorial experimental work was carried out to produce single tracks under different combinations of process parameters. A major application of this research work is to develop more flexible machine configurations applicable to different materialsThis work was carried out, in part, with the support of grants from the European Commission project IREBID (FP7-PEOPLE-2009-IRSES-247476) and the Spanish Science and Innovation Minister project TECNIPLAD (DPI2009-09852

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