Function Of Process Parameters Research Articles

Characterizing the as-built surface topography of Inconel 718 specimens as a function of laser powder bed fusion process parameters

Purpose The ability to use laser powder bed fusion (LPBF) to print parts with tailored surface topography could reduce the need for costly post-processing. However, characterizing the as-built surface topography as a function of process parameters is crucial to establishing linkages between process parameters and surface topography and is currently not well understood. The purpose of this study is to measure the effect of different LPBF process parameters on the as-built surface topography of Inconel 718 parts. Design/methodology/approach Inconel 718 truncheon specimens with different process parameters, including single- and double contour laser pass, laser power, laser scan speed, build orientation and characterize their as-built surface topography using deterministic and areal surface topography parameters are printed. The effect of both individual process parameters, as well as their interactions, on the as-built surface topography are evaluated and linked to the underlying physics, informed by surface topography data. Findings Deterministic surface topography parameters are more suitable than areal surface topography parameters to characterize the distinct features of the as-built surfaces that result from LPBF. The as-built surface topography is strongly dependent on the built orientation and is dominated by the staircase effect for shallow orientations and partially fused metal powder particles for steep orientations. Laser power and laser scan speed have a combined effect on the as-built surface topography, even when maintaining constant laser energy density. Originality/value This work addresses two knowledge gaps. (i) It introduces deterministic instead of areal surface topography parameters to unambiguously characterize the as-built LPBF surfaces. (ii) It provides a methodical study of the as-built surface topography as a function of individual LPBF process parameters and their interaction effects.

Computational modeling of multi-track multi-layer laser directed energy deposition process

This study presents the development of a 3D fully coupled thermomechanical finite element model to evaluate the melt pool geometry, defects, and micro-hardness of multi-track multi-layer deposition in the powder feed laser-directed energy deposition (LDED) technique. Fabrication strategies can significantly affect the melt pool geometry and material behavior of the manufactured components. Understanding the effect of process parameters in a multi-track multi-layer LDED is important. Optimal process parameters are crucial for achieving high-quality deposition in terms of deposition geometry and integrity. The model can aid in mitigating issues such as inadequate inter-track or track-substrate fusion, porosity, cracks, and other defects. A multi-track multi-layer finite element model (FEM) can realistically predict melt pool evolution, mechanical properties, and defects in laser-LDED. This work focuses on the development of a fully coupled thermomechanical model for multi-track multi-layer deposition processes using ABAQUS®. The finite element framework employs Johnson-Cook’s flow stress model for constitutive behavior and the Koistein-Marburger equation for predicting hardness. Two tracks and two layers of SS316L powder are deposited on an SS304 substrate in finite element simulations and experiments. The model has been validated for the melt-pool depth in the substrate, deposition geometry, heat-affected zone, and hardness. It has been observed that there is a ∼10 % error in the prediction of melt pool geometry characterization and a ∼12 % error in hardness as compared to experimental results. The melt-pool width, depth, substrate dilution, and hardness have been characterized as a function of process parameters via simulations and experiments. The model is capable of predicting inter-track and interface defects. In addition, the effect of interlayer cooling on the melt-pool geometry and hardness has been studied.

Controlling Mechanical Properties of Medical-Grade Scaffolds through Electrospinning Parameter Selection.

Electrospinning (ES) is a versatile process mode for creating fibrous materials with various structures that have broad applications ranging from regenerative medicine to tissue engineering and surgical mesh implants. The recent commercialization of this technology for implant use has driven the use of resorbable electrospun products. Resorbable electrospun meshes offer great promise as temporary implants that can utilize the layer upon layer method of additive manufacturing to incorporate porosity as a function of process parameters into a scaffold structure. The interconnected porosity and feature size known to ES have previously been observed to hold great potential for simulating the natural cellular environment of soft tissue. This microstructure, proper degradation kinetics, and mechanical properties combine to provide the design basis for artificial tissue structures that could aid in not only wound healing but also true tissue engineering and regenerative medicine. While current advancement in the field is understood to be limited by material properties, the importance of optimizing mechanical properties with currently available materials should not be overlooked. This work investigated the process parameter effects and interactions that control the structure-property relationship for a range of medical-grade aliphatic polyester materials with a range of intrinsic properties. An ε-caprolactone homopolymer (PCL), l-lactide homopolymer (PLLA), and Lactoflex, a copolymer with intermediate properties relative to the homopolymers, were characterized before, during, and after the additive manufacturing process. The interacting effects of process parameters, distance to collector, and dispensing rate were shown to produce variable-density, nonwoven scaffold structures. The resorbable mesh scaffolds of PLLA, PCL, and Lactoflex demonstrated a broad range of mechanical properties (approximately 1-10 MPa ultimate tensile strength and 5-390 MPa tensile modulus). Postprocessing of scaffolds demonstrated removal of solvents and preservation of micrometer-sized features. Resorbable polymers and electrospinning can produce scaffold materials with excellent features and offer tremendous potential in the field of implantable resorbable devices.

Investigating battery black mass leaching performance as a function of process parameters by combining leaching experiments and regression modeling

The current paper investigates the leaching phenomena of industrially produced Li-ion battery waste in hydrometallurgical recycling processes. Specifically, it studies the leaching reactions of NMC111-type (LiNi1/3Mn1/3Co1/3O2) black mass, as well as the statistical behavior of cathode material leaching yields under varying process conditions. The investigated process variables include reductive agent concentrations (Fe2+, Cu, H2O2) as well as process temperature, whereas S/L ratio (200 g/L) and initial acidity (2 M H2SO4) were kept constant. At lower temperatures (T = 30 °C), copper was found to act as the predominant reductant, enabled by the presence of sufficient solution iron concentrations (≥0.4 g/L Fe). Conversely, at higher temperatures (T ≥ 50 °C), the reductive capability of aluminum was substantially increased due to its decreased tendency for passivation. In contrast to copper, dissolved iron did not notably affect the reductive behavior of aluminum. The efficiency of metallic reductants initially present within the black mass was high, reaching cathode metal leaching yields above 90 % at 70 °C. A predictive leaching model for black mass leaching yields was built via regression analysis and can be used to indicate pregnant leach solution (PLS) composition – via leaching yields – after two hours of processing as a function of the investigated process variables. The model showed leaching temperature to be the most impactful parameter, while also indicating a higher reductive efficiency of copper when compared to equimolar additions of H2O2. As a case example, LFP (LiFePO4) cathode powder was also investigated as an alternative reductant/catalysis species (Fe2+) source in the system and was found to increase cathode metal leaching yields almost as much as FeSO4 while also resulting in a remarkable increase in Al dissolution in the process.

Coupled fluid-structure-interaction simulation approach for correction of the thermal tool elongation to improve the milling precision

During milling operation, the position of the tool centre point (TCP) is affected by structural displacements, which are caused by force loads and heat input inside the machine as well as machining induced thermal loads. These thermal loads result in considerable thermal deformations of tool holder, tool, and accordingly the TCP position. They can be summed up to about tens of microns and compromise the dimensional accuracy. The objective was to develop an integrated, numerical simulation-based approach for future TCP correction for a milling process using characteristic diagrams. For this, a complex Fluid-Structure-Interaction (FSI) simulation model predicts the uni-axial displacement in the longitudinal direction of the TCP due to a specified process heat source at the tool tip. As a partial result, the simulation has reached its performance limits, under the restriction of a reasonable simulation time in order to produce characteristic diagrams for application on a milling machine. The calculated thermally induced displacement can be further processed with the aid of Design of Experiments (DoE) and response surface methodology (RSM), depending on the thermal process load and coolant volume flow rate. That results in characteristic diagrams for the displacement as a function of process parameters. In this study the calculated value for thermally induced TCP displacement covers a span from 10 μ\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$\\upmu$$\\end{document}m to 80 μ\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$\\upmu$$\\end{document}m, with a strongly nonlinear behaviour. Subsequently, this forms the basis for a future implementation of characteristic diagrams in the machine control system for online correction of thermal tool errors.

Stable DC vacuum arc plasma generation from a 100 mm TiB2 cathode

Titanium diboride exhibits outstanding properties for hard and wear resistant coatings. However, efficient physical vapor deposition (PVD) processing through DC vacuum arc, with a deposition rate unreachable for any other PVD technique, is comparatively unexplored for TiB2 thin films due to challenges associated with the film synthesis process. In this work, we used an industrial scale arc plasma source having a plane cathode of 100 mm in diameter and a permanent magnet on its back side. We present analysis of the cathode surface, plasma generation/composition, as well as analysis of collected macroparticles. The cathode weight loss and the amount of generated macroparticles were measured as a function of process parameters (arc current and pressure, in both Ar and N2 gas). Plasma analysis shows average ion energies around 120 and 25 eV for Ti and B, respectively, and plasma ion composition of approximately 50 % Ti and 50 % B. The cathode weight loss was around 0.3–0.5 g/min, of which at least 25 % is estimated to be macroparticles. Notably, the intensity of the macroparticle generation was reduced with an increase in N2 pressure. Altogether, the results show a stable and reproducible plasma generation process and a high potential for the use of the cathodic arc as an efficient and useful method for deposition of metal borides.

Recycling of glass waste and spent alkaline batteries cathodes into insulation materials

Expanded glass with thermal and acoustic insulation properties are obtained from a foaming blend composed of 97% glass waste and 3% expanding agent. This latter is a blend of carbon and manganese oxides, recovered from exhausted alkaline batteries. The samples are produced after heating the mixture in a ventilated furnace at temperatures between 850 and 950 °C, for times between 15 and 60 min. Mechanical, thermal and acoustic properties are characterized as a function of process parameters. The glass foam samples have densities in the range of 290–350 kg/m3, porosity of 86–90%, thermal conductivity values of 107–120 mW m−1 K−1, noise reducing factors of 0.2–0.3 and compressive strengths up to 4.6 MPa. Although the resulting insulating performances are not as outstanding as those of polymer foams or mineral wool, these materials can emerge as competitive candidates for applications requiring low weight and moderate thermal and acoustic insulation properties, in combination with non-flammability and high temperature load bearing-capacity. Moreover, the use of 100% recycled raw materials limits the energy and the resource required for their production, if compared to those needed for the extraction, transportation, and processing of primary raw materials, making these foams attractive also in terms of environmental impact.

Evolution of microstructure and properties of CoCrFeMnNi high entropy alloy fabricated by selective laser melting

Abstract CoCrFeMnNi high entropy alloy was prepared by selective laser melting as a function of processing parameters by adopting the single factor variable method. The influence of process parameters on the microstructure and mechanical properties was investigated in detail. The results show that the alloy maintained a single-phase fcc structure, the microstructure is anisotropic and shows the presence of a high density of dislocations accumulated and entangled inside the grains. The ductility has a significant influence on the level of porosity, which in turn depends on the process parameters. Especially with the variation of hatch spacing, the elongation at break differs by at most 20.9 %.

Process-Structure-Property Relationships of Laser Powder Bed Fusion Lattice Structures

Abstract Lattice structure metamaterials offer a variety of unique and tailorable properties, yet industrial adoption is slowed by manufacturability and inspection-related difficulties. Despite recent advances in laser powder bed fusion additive manufacturing, the sub-millimeter features of lattices are at the edge of process capabilities and suffer from low geometric quality. To better understand their complex process-structure-property (PSP) relationships, octahedron structures were manufactured across a power spectrum, inspected, and mechanically tested. X-ray computed tomography was used to characterize lattice geometry, and demonstrated that lattice strut geometry measures, increased significantly as a function of laser power. Furthermore, lattices are shown to exhibit a direct correlation between laser power and mechanical performance metrics. Performance variations up to 60% are shown as a function of process parameters despite nominally identical geometry. Significant geometry variations are found to be the cause of performance variation, while material properties as measured by microindentation hardness are constant across the studied parameter range. PSP relationships are modeled, and the limitations of these models are explored. It was found that resulting models can predict mechanical performance based on geometric characteristics with R2 values of up to 0.86. Finally, mechanistic causes of observed performance changes are discussed.

A comprehensive study of A357 alloy printability via laser metal deposition

Laser metal deposition (LMD) is one of the most important techniques in additive manufacturing (AM) thanks to the high flexibility of the process, which makes the production of free-form shapes possible. However, working with some materials presents some challenges. This is the case with aluminum alloys due to their reflectivity and their very high thermal conductivity. On the other hand, aluminum and its alloys are quite important in several industrial fields, including aerospace, among others, due to their mechanical properties with low density. In this work, LMD is applied on an A357 aluminum alloy. The techniques are investigated moving from a single-track approach up to multi-pass and multi-layer strategies. Densities, microstructures and mechanical performance are investigated as a function of process parameters. Porosities are reduced, resulting in overall densities of over 97% and microhardness values are in the range of 80–100 HV. Differences in mechanical performance are analysed considering different building directions, showing a dependency on loading direction and the distance from the substrate. Tensile tests reveal a promising performance for further investigation with the LMD technique. The obtained evidence is interesting for future trends where large and light components are required while maintaining the mechanical performance of traditional manufacturing methods. Moreover, a comprehensive study is done for the first time on A357 alloy that is deeply used in the aerospace and automotive fields. The investigation and definition of the best process parameters open the possibility of exploiting LMD technology in the production of wide components or for adding features to already existing components overcoming some limits of other AM technologies.

Understanding Causalities in Organic Photovoltaics Device Degradation in a Machine-Learning-Driven High-Throughput Platform.

Organic solar cells (OSCs) now approach power conversion efficiencies of 20%. However, in order to enter mass markets, problems in upscaling and operational lifetime have to be solved, both concerning the connection between processing conditions and active layer morphology. Morphological studies supporting the development of structure-process-property relations are time-consuming, complex, and expensive to undergo and for which statistics, needed to assess significance, are difficult to be collected. This work demonstrates that causal relationships between processing conditions, morphology, and stability can be obtained in a high-throughput method by combining low-cost automated experiments with data-driven analysis methods. An automatic spectral modeling feeds parametrized absorption data into a feature selection technique that is combined with Gaussian process regression to quantify deterministic relationships linking morphological features and processing conditions with device functionality. The effect of the active layer thickness and the morphological order is further modeled by drift-diffusion simulations and returns valuable insight into the underlying mechanisms for improving device stability by tuning the microstructure morphology with versatile approaches. Predicting microstructural features as a function of processing parameters is decisive know-how for the large-scale production of OSCs.

A new control parameter to predict micro-warping-induced job failure in LPBF of TI6AL4V titanium alloy

Laser powder bed fusion (LPBF) includes a few printing techniques widely used, in recent years, concerning the additive manufacturing of Ti6Al4V alloys. These produced parts, typically utilized in sectors such as aerospace and biomedical, are characterized by very high added value. It is therefore fundamental to identify the influence of process parameters typical of LPBF technology on the occurrence of warping leading to process failure. This study deals with the characterization of single-track and “micro-scale” level warping phenomena which may lead to protrusion of material over the powder bed and process failure before normal termination. This phenomenon was investigated as a function of process parameters, referring also to the strength and ductility characteristics of the manufactured samples. With this purpose, several samples were printed using variable process parameters both in terms of line energy density (LED) values and in terms of laser power and speed combinations such as to guarantee constant LED values. For the samples that did not show significant micro-warping phenomena, in addition to the transversal and longitudinal geometric characterization of the single track, tensile tests were performed to determine both the resistance of the material and the ductility characteristics. The single tracks, for given process parameters, were printed on a homogeneous material substrate. For every single track, a microstructural and morphological transverse and longitudinal characterization has been carried out and the measured geometrical features were correlated to the process parameters. The obtained results allowed the identification of a new threshold parameter, indicating the limit operating conditions beyond which significant warping phenomena and process failure occur.

Correlation between Processing Parameters, Morphology, and Properties of Injection-Molded Polylactid Acid (PLA) Specimens at Different Length Scales.

Polylactic acid (PLA) is one of the most promising bioplastic representatives that finds application in many different areas, e.g., as single-use products in the packaging industry, in the form of mulch film for agriculture, or in medical devices. For the development of new areas, especially in terms of long-term applications and the production of recyclable products, the material properties controlled by processing must be known. The state of the art is investigations at the global scale (integral values) without consideration of local structure inhomogeneities and their influence on the material properties. In this work, morphological, thermal, and mechanical properties of injection-molded PLA tensile bars are investigated at different length scales (global and local) as a function of processing parameters. In addition to the processing parameters, such as melt temperature, mold temperature, and cooling time in the mold, the influence of the D-isomer content on the crystallization behavior and the resulting material properties are investigated. The material was found to form crystalline structures only when cooled in a mold tempered above Tg. In addition, PLA with a lower content of D-isomer was found to have a higher degree of crystallinity. Since the mechanical properties obtained by tensile tests could not be correlated with the degree of crystallinity, detailed analysis were performed showing a characteristic inhomogeneous morphology within the tensile bars. By means of micromechanical investigations on samples with different microstructure ranges, the relationship between local morphology and failure behavior could be explained.

Food aeration: Effect of the surface-active agent type on bubble deformation and break-up in a viscous Newtonian fluid: From single bubble to process-scale

Two continuous whipping devices, a rotor–stator (RS) and a narrow angular gap unit (NAGU), were used to produce aerated food with a 25% (v/v) gas fraction target. The liquid phase was a Newtonian model-solution containing 2% (w/w) of either whey proteins (WPC), sodium caseinate (SCN), or tween 20 (TW20). Strong differences emerged regarding gas incorporation and bubble size as a function of process parameters: namely, rotation speed and residence time. To improve understanding of the results obtained at pilot-scale, a second investigation consisting in the observation of the deformation and break-up of single gas bubbles has been undertaken using successively a Couette device and an impeller close to NAGU. For proteins, the observation of single bubble deformation and break-up showed that bubble break-up occurred by tip-streaming above a well-defined critical Capillary number Cac of 0.27 and 0.5 for SCN and WPC, respectively, whereas no break-up was observed with TW20 even though Ca reached 10. The poor foaming ability obtained with TW20 could be explained by a poor break-up mechanism, promoting coalescence and gas plugs at high shear instead of gas incorporation. Conversely, protein promote tip-streaming as the major break-up mechanism at low shear rate, explaining why rotation speed is not a key process parameter. Differences observed between SCN and WPC can be attributed to diffusion limitation for SCN when a much larger surface area is generated during aeration.

Thickness variation in contoured composite parts by vacuum infusion

Contoured laminates were produced by vacuum infusion (VI), and thickness variations were monitored dynamically as a function of process parameters. Process simulations were performed using finite element software (PAM-RTM), and predictions of thickness along the length of the laminate were compared with dynamic measurements. Initial simulations approximated the effects of corners on preform deformation and fabric draping behavior. Subsequent modifications to the simulation geometry and material properties were implemented to increase accuracy and more closely match experimental measurements. User-defined geometry (UDG) simulations were used to predict both the maximum corner deviation and the area of corner deviation with greater accuracy. The present study demonstrates a workflow for use of analytical tools to design and control vacuum infusion processes. The workflow leverages process monitoring and modified process simulation tools to provide insight into parametric effects and to guide process modifications to reduce product variability.

Effects of Processing Parameters on the Microstructure and Mechanical Properties of Intermetallic Matrix Composites

In the realm of advanced materials, Intermetallic Matrix Composites (IMCs) have garnered significant attention due to their potential for high-temperature applications. This study systematically investigates the influence of various processing parameters on the microstructure and mechanical properties of IMCs. Utilizing a combination of powder metallurgy and subsequent heat treatments, samples were prepared under varied conditions. The microstructural evolution was meticulously examined using Scanning Electron Microscopy (SEM) and Transmission Electron Microscopy (TEM), revealing distinct morphological changes as a function of processing parameters. Quantitative analysis demonstrated a direct correlation between processing conditions and the distribution, size, and morphology of the reinforcing phases. Mechanical testing, including tensile, compression, and hardness tests, was conducted to evaluate the resultant properties. The findings indicate that specific processing conditions can be optimized to achieve a desirable balance between ductility and strength. Notably, a unique set of parameters was identified that yielded an unprecedented combination of high strength and ductility, challenging the conventional trade-off paradigm in composite materials. This research underscores the critical role of processing in tailoring the microstructure and, consequently, the mechanical performance of IMCs, paving the way for their application in demanding environments.

XANES Studies of Zinc Tin Oxide Films Deposited by Atomic Layer Deposition: Revealing Process-Structure Relationships for Amorphous Oxide Semiconductors

Amorphous oxide semiconductors have grown in technological relevance in displays, information technology, energy, and catalysis. Recent research efforts have converged on the need to develop design principles for the electronic structure of these materials. Here, we systematically vary the cation composition and annealing temperatures of zinc tin oxide films using atomic layer deposition (ALD) and study their process-structure relationships with synchrotron X-ray absorption near-edge spectroscopy (XANES). Measurements of the O K-edge, Sn M-edge, and Zn L-edge are analyzed with ab initio and nonlinear statistical modeling to understand the changes in geometric and electronic structure of the films. A key finding from this approach is the ability to measure the changes in the relative contribution of the Zn and Sn s orbitals to the density of states near the conduction band minimum. Furthermore, we identify and delineate critical process-structure design principles when working with amorphous oxide semiconductor (AOS) material systems: (1) use of complementary diffraction and absorption spectroscopy techniques to characterize the as-deposited coordination environment; (2) accounting for gradual and abrupt changes in coordination environment as a function of processing parameters (stoichiometry, annealing, etc.); (3) revealing and exploiting the relevant knowledge and interdependence of coordination environments, orbital hybridizations, the density of states, and band structures. In the future, this multimodal X-ray analysis and modeling framework can be applied to understand the process-structure relationships needed to optimize AOS performance in devices.

Microstructure and mechanical properties of laser metal deposited Ti6Al4V alloy with near equiaxed β grain structure

Ti6Al4V alloy produced by additive manufacturing are generally characterized by their columnar β grain structure and the resulting anisotropy in mechanical properties as a critical challenge in engineering applications. In the present work, a near equiaxed β grain structure is obtained in the Ti6Al4V alloy thin-wall specimens produced by laser metal deposition through tailoring laser power and interlayer dwell time. Microstructure, texture, and mechanical properties of the as-deposited alloys are investigated as functions of processing parameters. When the interlayer dwell time is fixed at 10 s, the columnar β grain structure changes to a near equiaxed morphology, and the grain width (size) decreases with increasing laser power from 1200 W to 1500 W. Recrystallization of the previously deposited layers during processing is suggested to be responsible for the formation of the near-equiaxed β grain structure. All the as-deposited alloys consist of a weakly textured α phase and the β phase at room temperature. The as-deposited alloys with the near-equiaxed β grains show superior mechanical properties, as evidenced by large elongation values up to 14%.

Heavy Oil Fly Ash as an Adsorbent for Methylene Blue Removal from Aqueous Solution

The industry produces a large amount of solid waste that has very bad effects on the environment. The application of waste material adsorbents for waste materials treatment has become of greater interest. Heavy oil fly ash (HOFA) is hazardous industrial solid waste which produces from the combustion of heavy fuel oil in power plants. The work aims to investigate using waste material heavy oil fly ash (HOFA) after modification to activated carbon (AC) as an adsorbent of methylene blue (MB) in an aqueous solution. Chemical and physical analyses were conducted to characterize the HOFA produced as a by-product of an electrical power station. BET analysis showed the surface area was 1.6 m2/g and the surface area was enhanced by the activation process to 63.7 m2/g and the pore width to 553.5A. SEM showed a change in the nature of the surface of the martial by increasing the porosity. Adsorption studies were performed by batch experiments as a function of process parameters. The removal percentage increased with the increase of the adsorbent to 1.5g, the amount was selected as the optimum dosage. The removal percentage decreased with an increase the entail dye concentration and limited difference in pH variables. The experimental adsorption data was represented with Langmuir, Freundlich, and Tempkin isotherms. The data fitted well to the Freundlich model as multilayer adsorption.

A physics-based modeling framework to assess the cost scaling of additive manufacturing, with application to laser powder bed fusion

Purpose This study presents a framework to estimate throughput and cost of additive manufacturing (AM) as related to process parameters, material thermodynamic properties and machine specifications. Taking a 3D model of the part design as input, the model uses a parametrization of the rate-limiting physics of the AM build process – herein focusing on laser powder bed fusion (LPBF) and scaling of LPBF melt pool geometry – to estimate part- and material-specific build time. From this estimate, per-part cost is calculated using a quantity-dependent activity-based production model. Design/methodology/approach Analysis tools that assess how design variables and process parameters influence production cost increase our understanding of the economics of AM, thereby supporting its practical adoption. To this aim, our framework produces a representative scaling among process parameters, build rate and production cost. Findings For exemplary alloys and LPBF system specifications, predictions reveal the underlying tradeoff between production cost and machine capability, and look beyond the capability of currently commercially available equipment. As a proxy for build quality, the number of times each point in the build is re-melted is derived analytically as a function of process parameters, showcasing the tradeoff between print quality due to increased melting cycles, and throughput. Originality/value Typical cost models for AM only assess single operating points and are not coupled to models of the representative rate-limiting process physics. The present analysis of LPBF elucidates this important coupling, revealing tradeoffs between equipment capability and production cost, and looking beyond the limits of current commercially available equipment.