Selective Laser Melting Method Research Articles

INVESTIGATION OF THE STRUCTURE AND PROPERTIES OF FERROUS NICKEL ALLOYS AFTER MOLDING BY SELECTIVE LASER MELTING

Problem statement. The selective laser melting method is a promising technology for the production of parts from heat-resistant alloys. Traditional methods of manufacturing such parts require additional technological equipment and processing, which increases the time of production preparation and, as a result, to the creation of a large number of raw materials. Selective laser melting allows you to produce parts of a complex configuration without the need for additional equipment. Molding of parts using additive technologies, which ensure a reduction in product preparation time, mechanical processing operations, and an increase in the efficiency of material use. Their application in the technological cycle of manufacturing products is an urgent task today. However, before the introduction into the technological process of forming products from heat-resistant alloys by the selective laser melting method, it is necessary to carry out a comprehensive analysis of the mechanical and technological characteristics of the material and its microstructure, which affects the final properties of the parts. The purpose of the article. Investigation of the possibility of implementing the selective laser melting method for the production of parts from strong alloys, analysis of the mechanical characteristics of the material, as well as the microstructure, which affects the final properties of the parts. Conclusions. Studies have shown that the selective laser melting method is effective for the production of complex parts from heat-resistant alloys. The obtained data on the mechanical properties after heat treatment of the Inconel718 alloy demonstrate its compliance with the requirements of the AMS 5662 standard and its suitability for working under extreme conditions. In the microstructure, highlighted features are revealed, which are characteristic of the selective laser melting method, as well as the presence of visible tracks and a special texture − elongated grains in the direction of growing parts. Research points to the potential of additive technologies in improving technological processes and properties of alloys for the production of heat-resistant alloy parts.

Comparison of fatigue behaviour and fracture toughness of cobalt chromium alloy fabricated by casting and selective laser melting methods

Co-Cr alloys are most commonly used base metal alloy in dentistry for the fabrication of many types of metallic substructures. They gained popularity due to their good mechanical properties and low cost. There are different techniques for fabrication of Co-Cr alloys which includes casting and DMLS technique. However, change in the fabrication techniques showed variation in mechanical properties. Forty Co-Cr samples each were made from two different techniques, Casting and DMLS. Fracture toughness was done with charpy’s impact test machine and fatigue behaviour test was done with nano universal testing machine. The samples were later observed under stereo electron microscope to assess the kind of failure. Unpaired t test revealed that there was statistically significant difference between two different groups. The mean difference of fracture toughness in Casting group was higher when compared with DMLS group. The number of fatigue cycles were higher in DMLS group than the casting group. Within the limitations of this in vitro study, casting group showed higher fracture toughness when compared to DMLS group, whereas fatigue limit was higher in DMLS group than casting group.

High-strength AlCoCrFeNi2.1 eutectic high entropy alloy skeleton with hollow brick wall structures by selective laser melting

In this work, a hollow brick wall structure was introduced into the preparation of AlCoCrFeNi2.1 EHEA to realize a skeleton structure by taking advantage of the good castability of eutectic high entropy alloys (EHEAs) and high cooling rate of selective laser melting (SLM). The effects of processing parameters on eutectic microstructure and mechanical properties of SLM-ed AlCoCrFeNi2.1 EHEA skeletons were investigated. With increasing volume energy density (VED), the microstructure along the building direction evolved from cellular structure to the coexistence of cellular and lamellar structures. The phases in the SLM-ed AlCoCrFeNi2.1 EHEA skeletons contained BCC/B2 and FCC phases. Under the VED of 137.25 J/mm3, SLM-ed skeletons with hollow brick wall structures had a compressive strength of 241.2 ± 4.2 MPa. The mechanical properties from tensile tests exhibited a yield strength of 1349.4 ± 12.4 MPa and an ultimate tensile strength of 1529.5 ± 12.8 MPa. The superior performance of the selective laser melting method was attributed to fine grain strengthening, dislocations strengthening, and heterogeneous structure of FCC and BCC/B2. This work provides possibilities for microstructure design and performance improvement of EHEAs and expands the avenue for developing advanced high-strength lightweight structural and energy-absorbing alloys.

Flow phenomena in laminar flow through streamlined and sharp-edged short monolithic structures

Monolithic structures of catalytic reactors offer low flow resistance, but their drawback is weak heat and mass transport. For transport intensification, innovative streamlined structures were designed, the walls of which are shaped like an airplane wing. Extensive CFD (Computer Fluid Dynamics) studies were performed for the streamlined and—for comparison—classic (sharp-edged) structures, covered flow phenomena, and heat transfer to channel walls. The streamlined structures were made using the SLM (Selective Laser Melting) method to perform heat transfer experiments that gave a satisfactory agreement with the CFD. Heat transfer for streamlined structures was, by CFD, more intensive than for the classical ones. CFD simulations showed a significant reduction of vortices in streamlined structures. The lack of an inlet vortex was demonstrated, for classic structures strongly limiting transfer properties. For the streamlined structures the outlet vortex even intensifies heat transport near the outlet of the channel. The CFD showed the flow patterns for the structures as well as the distribution of transport coefficients within the millimetre-sized channels.

Compressive Mechanical Behavior of Additively Manufactured 3D Auxetic Metamaterials with Enhanced Strength

Compared with 2D auxetic metamaterials, 3D auxetic metamaterials present better structural, mechanical, and functional properties, which are more applicable in many potential applications in engineering fields. Herein, three types of 3D star‐shaped auxetic (SSA) structures, re‐entrant and star‐shaped composite auxetic (RSA) structures, and star‐rhombic auxetic (SRA) structures with small unit cell are proposed and fabricated by selective laser melting method. The compressive behavior and energy absorption of the auxetic structures are explored and compared based on finite‐element method (FEM) verified by the compression test results of the sample. Meanwhile, the numerical results present good agreements with the experimental results in terms of deformation mode, Poisson's ratio, and compression behavior. The results reveal that SRA structures exhibit superior elastic modulus, compressive strength, and energy absorption than SSA and RSA structures, which stems from the auxetic effect, obstruction of rhombic structures to the deformation of inclined struts and more plastic hinges. It is precisely because of the obstruction of rhombic structures that SRA structures exhibit weakening auxetic characteristic and even no auxetic behavior during the higher strain range. In addition, the length of the structural strut presents a significant impact on the energy absorption performance and compression strength of all the structures.

Effects of process parameters on selective laser melting of Ti6Al4V-ELI alloy and parameter optimization via response surface method

Selective laser melting (SLM) allows for manufacturing intricate and accurate component designs that are challenging, expensive, or impossible to achieve using traditional methods. To achieve a high-quality final product with SLM, it is necessary to optimize the process parameters carefully. This optimization helps to minimize internal structural defects and control the microstructure. In this study, the optimum production parameters of Ti6Al4V alloy were determined using the Response Surface Method (RSM). The micro-CT analysis was utilized to calculate the relative densities of the samples fabricated using different production parameters. Furthermore, the influence of heat treatment, conducted below and above the β transformation temperature, on the mechanical properties was examined. The results were analyzed by considering the microstructure images obtained from Scanning Electron Microscope (SEM) and X-ray Diffraction (XRD) analysis. The optimum production parameters for the SLM method were found to be 80W laser power, 1125 mm/s scanning speed, 25 μm layer thickness, and 45 μm hatch distance. Samples created with these optimized parameters achieved 99.919% relative density, 1050 MPa ultimate tensile stress, and 13.8% elongation, surpassing the minimum standards outlined in ASTM F3001-14. Additionally, the systematic parameter reduction approach used in the study led to savings in both powder consumption and time in SLM, a method that could be applied to various metallic materials.

Biodegradable Magnesium Alloys for Personalised Temporary Implants.

The objective of this experimental work was to examine and characterise the route for obtaining demonstrative temporary biodegradable personalised implants from the Mg alloy Mg-10Zn-0.5Zr-0.8Ca (wt.%). This studied Mg alloy was obtained in its powder state using the mechanical alloying method, with shape and size characteristics suitable for ensuing 3D additive manufacturing using the SLM (selective laser melting) procedure. The SLM procedure was applied to various processing parameters. All obtained samples were characterised microstructurally (using XRD-X-ray diffraction, and SEM-scanning electron microscopy); mechanically, by applying a compression test; and, finally, from a corrosion resistance viewpoint. Using the optimal test processing parameters, a few demonstrative temporary implants of small dimensions were made via the SLM method. Our conclusion is that mechanical alloying combined with SLM processing has good potential to manage 3D additive manufacturing for personalised temporary biodegradable implants of magnesium alloys. The compression tests show results closer to those of human bones compared to other potential metallic alloys. The applied corrosion test shows result comparable with that of the commercial magnesium alloy ZK60.

Experimental and FEM investigation of BCC lattice structure under compression test by using continuum damage mechanics with micro-defect closure effect

The failure of the cellular structures and the prediction of their limit load and type of failure are essential in their design and applications. The isotropic Continuum Damage Mechanics (CDM) model of Lemaitre with micro-defect closure effect was considered to simulate the mechanical response of the BCC lattice structure under a compression test. Defects caused during the manufacturing process is considered an initial damage. The simulation results of the compression tests on the 316L Stainless Steel (SS) lattice structures, which were manufactured by the Selective Laser Melting method (SLM), and the experimental results have been compared. The same study was conducted on the AlSi10Mg manufactured lattice structures. FE simulation showed that the CDM model can predict the elastic modulus and yield strength of the lattice structure with good accuracy. The stress–strain curve of the lattice structure, obtained from the FE simulation, agrees well with the experimental results before the condensation. According to the conducted experiments, the failure mechanism for the considered cases is bending dominated with high plastic deformation at the connection area of nodes and struts. The present model predicts the state of damage of the structure with good accuracy and it is in agreement with the experimental results.

The effect of ultrasonic field on the microstructure and corrosion behavior of Fe-based amorphous coating applied to selective laser melting

This study was conducted to investigate the effect of the ultrasonic field on the preparation of amorphous/crystalline Fe-based coatings. For this purpose, Fe86.3Si 5.9B3.2Cr4.6 (wt%) powder was deposited on GTD-111 superalloy substrate with and without ultrasonic field by selective laser melting method. After coating, the corrosion behavior, microstructure, and hardness of the amorphous coating were investigated. The results showed that in conditions without ultrasonic vibration, the growth of grains starts in columnar form. At the same time, the use of an ultrasonic field inhibits columnar growth and creates equiaxed grains. In addition, the ultrasonic field increased the amorphous phase by 34.5%. This is attributed to the increased solidification rate caused by the cavitation effect. The experimental results of corrosion show that the self-corrosion current density of 6.83×10−7 A⋅cm2 is obtained due to the refinement of the microstructure and the increase of the amorphous phase. The wear results showed that the increase in the amorphous phase, as well as the decrease in the grain size, reduction in the grain ratio, and the increase in the tendency to equiaxed grains when using the ultrasonic field, reduce the coefficient of friction by 97%.

3D printed plastic molds utilization for WC-15Co cemented carbide cold pressing

In this work, we propose the use of 3D printing to make molds for pressing cemented carbide compacts. The fused material extrusion technique was used to make solid molds from polylactide for pressing a rectangular standard sample and a square cutting insert. The densification of the WC-15Co powder mixture combined with rubber (2%) was studied at pressures ranging from 41 to 121 MPa in the obtained molds. A comparative analysis of the density of powder compacts and sintered products and their properties was performed against their analogs formed by pressing in a hardened steel mold at a pressure of 210 MPa. Increasing the pressure in the plastic molds from 41 to 121 MPa led to an increase in the relative density of powder compacts from 65% to 70%. The relative density of powder compacts (75%) obtained by the steel mold pressing at a pressure of 210 MPa was only 5% higher. The density of sintered samples increased from 99.22% to 99.5% when the molding pressure was increased, which was only 0.29% lower than the density obtained by steel mold pressing. The hardness (1130–1160 HV) and fracture toughness (23.1–24 MPa m1/2) of samples produced in the plastic molds differed slightly from those produced in the steel molds (1170 HV and 24.4 MPa m1/2). In terms of the hardness and fracture toughness combination, the samples obtained by this technique were superior to those obtained by the selective laser melting method and were comparable to the samples obtained by sintering of powder compacts produced by various 3D printing methods (binder jetting, 3D gel printing, material extrusion).

Influence of Ni Contents on Microstructure and Mechanical Performance of AlSi10Mg Alloy by Selective Laser Melting.

To improve the tensile strength and wear resistance of AlSi10Mg alloys, a novel in situ synthesis method of selective laser melting (SLM) was used to fabricate the Ni-reinforced AlSi10Mg samples. The eutectic Si networks formed around the α-Al crystals by diffusion and transportation via Marangoni convection in the SLM process. Moreover, the XRD and TEM results verified that the Al3Ni nanoparticles were created by the in situ reaction of the Ni and aluminum matrix in the Ni/AlSi10Mg samples. Therefore, the microstructure of the Ni-containing alloys was constituted by the α-Al + Si network + Al3Ni phases. The dislocations accumulated at the continuous Si network boundaries and cannot transmit across the dislocation walls inside the Si network. SEM results revealed that the continuity and size of eutectic Si networks can be tailored by adjusting the Ni contents. Furthermore, the Al matrix also benefited from the Al3Ni nanoparticles against the dislocation movement due to their excellent interfacial bonding. The 3Ni-AlSi10Mg sample exhibited high mechanical properties due to the continuous Si networks and Al3Ni nanoparticles. The tensile strength, elongation, Vickers hardness, friction coefficient, and wear volumes of the 3Ni-AlSi10Mg samples were 401.15 ± 7.97 MPa, 6.23 ± 0.252%, 144.06 ± 0.81 HV, 0.608, 0.11 mm3, respectively, which outperformed the pure AlSi10Mg samples (372.05 ± 1.64 MPa, 5.84 ± 0.269%, 123.22 ± 1.18 HV, 0.66, and 0.135 mm3).

Fiber laser beam welding of additive manufactured 316L austenitic stainless steel with wrought 2507 super duplex and wrought 904L super austenitic stainless steels: Crystallographic texture, microstructure, and mechanical properties

In this study, 316L parts were produced by selective laser melting (SLM) method, one of the additive manufacturing (AM) processes. Since the size limits of the SLM system prevent large parts from being produced in one piece, there is a need to weld the parts produced with SLM to each other in a final process as an alternative option. For this reason, AM 316L parts are joined with full penetration by fiber laser welding. Welded joints of metals with different properties are widely used in various industries. Accordingly, welding combinations of AM 316L and wrought (W) 2507 super duplex stainless steel (W2507) and wrought (W) 904L super austenitic stainless steel (W904L) sheets, which are stainless steel types with superior mechanical properties, were carried out. Weldability, microstructure, texture, and mechanical properties of AM316L-AM316L, AM316L-W2507, and AM316L-W904L stainless steels welded by fiber laser welding method were investigated in detail. According to the results obtained, it was observed that the as-built AM 316L microstructure consists of cellular grains, and the AM316L-AM316L, AM316L-W2507, and AM316L-W904L laser welded joints are composed of a fine microstructure. While no pores and porosity were observed in As-built AM 316L, nano-sized particles were seen in welded joints' transmission electron microscope (TEM) images. According to EBSD analysis, epitaxial solidification was observed in the weld center of all samples, while grain orientations were mostly random. According to the kernel average misorientation (KAM) analysis, a high dislocation density was detected, especially at the weld metal grain boundaries of the AM316L-W2507 sample. Again in this sample, the lowest grain orientation spread (GOS) value and the highest Taylor Factor value were determined. Depending on the laser welding process, it was determined that some grains in the weld metal center of all samples showed a relatively strong texture (<011>//welding direction). In contrast, the grains in other parts of the weld metal (WM) showed a weaker texture. According to the mechanical test results, the welded joints' mechanical properties were generally lower than the as-built AM316L, W904L, and W2507 base metals. Among welded joints, the highest tensile and yield strength was found in the AM316L-W2507 sample, while the highest ductility was found in the AM316L-W904L sample. It has been determined that the toughness results are very close to each other. As a result of the tensile and impact tests, it was seen that the fractures took place in the ductile mode.

Selective laser melting fabrication and mechanical properties of CLP-type Al cellular auxetic metamaterials with triply periodic minimal surfaces

In this work, we fabricated triply periodic minimal surface-structured CLP-type (TPMS-CLP, CLP is the abbreviation of Crossed Layers of Parallels) Al cellular metamaterials by a selective laser melting (SLM) method using pure Al powder as raw material and investigated their mechanical failure mechanism and the effects of wall thickness on their mechanical properties. The results showed that the Poisson's ratio of as-prepared TPMS-CLP cellular metamaterials was as low as −1.14 when the strain was smaller than 30%, and their mechanical properties were improved with increasing the wall thickness of their structural units. This work provides a new strategy for designing auxetic materials potentially applicable to many areas of protection engineerings.

Analysis of Phenomenon of Plasticity Loss of Steel Core Made by Selective Laser Melting Method in Zone of Pressure Mould Conformal Cooling Channel.

This paper presents the results of testing the mechanical properties of maraging steel 1.2709 that were obtained by the SLM method under uniaxial and triaxial states of stress. The triaxial state of stress was realised by making circumferential notches in the samples with different radii of rounding. The specimens were subjected to two types of heat treatment, which consisted of ageing at 490 °C and 540 °C for 8 h. The results of the tests that were conducted on the samples were considered as references and compared with the results of the strength tests that were conducted directly on the SLM-made core model. Differences were found between the results of these tests. Based on the experimental results, the relationship between the equivalent strain of the specimen in the bottom of notch εeq and triaxiality factor η was determined. Function εeq = f(η) was proposed as a criterion for the decrease in the plasticity of the material in the area of the pressure mould cooling channel. Using the FEM method, equivalent strain field εeq and triaxiality factor η were determined in the conformal channel cooled core model. Based on the proposed criterion of plasticity loss and the results of numerical calculations, it was shown that the values of equivalent strain εeq and triaxiality factor η in the core that was aged at 490 °C did not meet this criterion. On the other hand, the values of strain εeq and triaxiality factor η did not exceed the safety limit when ageing was carried out at 540 °C. The plasticity loss method presented in this paper assumes that the value of the triaxiality factor in the vicinity of the channel is influenced by the shape, cross-sectional dimensions and trajectory of the channel axis. Using the methodology proposed in this paper, it is possible to determine the value of allowable deformations in the cooling channel zone and to determine whether the heat treatment applied to the SLM steel does not cause an excessive reduction in the plastic properties.

Effects of process parameters on surface quality and mechanical performance of 316L stainless steel produced by selective laser melting

Selective laser melting (SLM) is a commonly used additive manufacturing technique for 316L stainless steel. In this study, the process parameters of 316L stainless steels fabricated by SLM method on surface quality and mechanical performance were investigated. The SLM method parameters and energy density significantly affect the mechanical performance and surface quality. Laser power and real spot size were kept constant at 370 W and 0.12 mm, respectively. The effect of different scanning speeds (900–1100–1300 mm/s), layer thicknesses (0.04–0.05–0.06 mm) and scanning gaps (0.09–0.1–0.11 mm) were analyzed. The increase in scanning speed affected the surface quality negatively. The highest mechanical performance was obtained at the laser power 370 W, scanning speed 1100 mm/s, layer thickness 0.04 mm, scanning gap (space) 0.1 mm, real spot 0.12 mm, overlap ratio 0.833 % and energy density 84.09 J/mm3. As a result of the study, it was observed that the mechanical performances were improved by increasing the input energy density.

Influence of parameters of molding by the selective laser melting method on product quality

Purpose. The development and application of additive technologies, which have a high rate of material utilization and significant production flexibility in the case of single and small-scale production, are relevant for solving various types of engineering problems. The final mechanical, technological and operational characteristics of products obtained by additive technologies are affected by a large number of initial parameters that can be varied in order to obtain the necessary properties of the material. The purpose of this work is to study the influence of the parameters of shape formation by the method of selective laser melting, in particular the scanning plan, on the quality of the material and the productivity of production. The methods. To achieve the goal, studies of the microstructure of products obtained by different scanning plans were carried out using optical microscopy, during which the shape of a single track, as well as the structure of the material in different directions of the laser beam, were analyzed. Findings. The effect of particle size, the mechanism of formation of a metal product during selective laser melting is analyzed. The influence of the scanning plan on the porosity, strength, and productivity of manufacturing by the method of selective laser melting is shown. The correct choice of technological parameters, such as the power and speed of the laser beam, the thickness of the metal powder layer, the scanning step between two adjacent single tracks, ensures the minimization of the number and size of defects (pores, cracks, shells) in the product material. The originality. The process of metal powder melting in the process of shaping products by the method of selective laser melting is analyzed. The scheme of formation of a single track is obtained in the case of choosing different scanning schemes. A list of technological parameters, the variation of which affects the properties and quality of the product, has been formed. Practical implementation. The use of additive technologies for the molding of products in single and small-batch production allows to reduce the time of production preparation and reduce the amount of waste. When choosing technological parameters, one should understand their dependence on the final properties of the finished product, because the method of selective laser melting allows to obtain products of different porosity, strength and other properties.

TOPOLOGICAL OPTIMIZATION OF THE ROCKER ARM

The focus of this paper is to compare the results of topological optimization (TO) of the rocker arm for following 3D printing out of AISI 316L stainless steel by the Selective Laser Melting (SLM) method. We used the Altair Inspire software to optimize the shape of the rocker arm. Two variants of optimization were created, first, a variant of optimization without the Shape Control function was carried out, which resulted in a complex mechanical component with an organic shape. This bionic design means more support for the SLM method of Additive Manufacturing (AM) and worse surface quality after their removal. Therefore, a second variant of optimization was produced with the application of the Shape Control function, which positively affects manufacturability and postprocessing. The use of shape control reduced the amount of supports to a minimum, helping to improve the surface finish.

Digital Evaluation of Trueness and Fitting Accuracy of Co-Cr Crown Copings Fabricated by Different Manufacturing Technologies.

The dentistry industry has seen a number of exciting new advancements in recent years, many of which have been made possible by the introduction of automated technologies such as computer-aided design and computer-aided manufacturing (CAD/CAM). Despite the fact that these new approaches simplify the fabrication process in favor of decreased material consumption and improved time efficiency, it is possible that they may have an effect on the prosthesis's fitness, which in turn may affect how long they will last. The purpose of this in vitro study was to evaluate the trueness and fitness of cobalt-chromium (Co-Cr) crown copings fabricated by selective laser melting (SLM), milling, and conventional casting methods. A zirconium die was fabricated and scanned with a laboratory scanner to manufacture the Co-Cr metal copings for three groups (n = 12). In group A, the copings were fabricated by a 3D printing technique called SLM; in group B, the copings were fabricated by the milling technique; and in group C, the copings were fabricated by the conventional lost-wax method. After fabrication, the trueness and the internal fitness of the copings were evaluated using a metrology software program (Geomagic Control X, 3D Systems Inc., Rock Hill, SC). The one-way ANOVA and Tukey's honestly significant difference test were used to statistically analyze the data. The highest root mean square (RMS) value of trueness was for CAD/CAM milling, and the highest mean of horizontal gaps was for the casted (lost-wax technique) group. There were highly significant differences in the mean RMS value of trueness and the mean horizontal gaps between the three groups. The fabrication method of Co-Cr crown copings has an effect on the trueness and fitness of the copings.

Investigation of the melt track geometry during selective laser melting of CuSn10

The CuSn10 alloy (bronze with 10% tin) has remarkable mechanical properties, including good elongation and medium hardness. Additive manufacturing of this powder compound is developing at a fast rate. In this study, optimization of the process parameters of the selective laser melting method was carried out to manufacture CuSn10 compounds. In addition, a numerical model for the simulation of the melt pool behavior was created by utilizing the Ansys 2021 R1 software, and a comparison was carried out between predicted numerical data and the obtained experimental results. The formation conditions of various melt traces were modeled, measured and validated for this aim. In the experimental stage, a constant laser power of 95 W was used, and the effect of the variation of the scanning speed was studied between 10 and 1500 mm/s. The results showed that the variation of the scanning speed is not enough, and optimization must be carried out by including other process parameters. This indicates that by adjusting the process parameters to have a 365 W power, the liquid phase can be achieved in the production process.

A Novel Feature-Based Manufacturability Assessment System for Evaluating Selective Laser Melting and Subtractive Manufacturing Injection Moulding Tool Inserts

Challenges caused by design complexities during the design stages of a product must be coordinated and overcome by the selection of a suitable manufacturing approach. Additive manufacturing (AM) is capable of fabricating complex shapes, yet there are limiting aspects to surface integrity, dimensional accuracy, and, in some instances, design restrictions. Therefore, the goal is essentially to establish the complex areas of a tool during the design stage to achieve the desired quality levels for the corresponding injection moulding tool insert. When adopting a manufacturing approach, it is essential to acknowledge limitations and restrictions. This paper presents the development of a feature-based manufacturability assessment system (FBMAS) to demonstrate the feasibility of integrating selective laser melting (SLM), a metal-based AM technology, with subtractive manufacturing for any given part. The areas on the tool inserts that hold the most geometrical complexities to manufacture are focused on the FBMAS and the design features that are critical for the FBMAS are defined. Furthermore, the structural approach used for developing the FBMAS graphical user interface is defined while explaining how it can be operated effectively and in a user-friendly approach. The systematic approach established is successful in capturing the benefits of SLM and subtractive methods of manufacturing, whilst defining design limitations of each manufacturing method. Finally, the FBMAS developed was validated and verified against the criteria set by experts in the field, and the system’s logic was proven to be accurate when tested. The decision recommendations proved to correlate with the determined recommendations of the field experts in evaluating the feature manufacturability of the tool inserts.