Manufacturing Of Parts Research Articles

Cost–effective additive manufacturing of metal parts using pneumatic extrusion: investigation of the sintering process

Purpose The purpose of this study is to develop a low-cost and efficient method for 3D printing CuSn15 bronze alloy parts using a pneumatic extrusion system. By avoiding complex processes such as filament preparation and solvent/catalytic debinding, the study aims to streamline the low-cost production process of metallic components while maintaining high mechanical performance. The research also seeks to evaluate the effects of different sintering temperatures and times on the mechanical properties of the printed parts. Design/methodology/approach A simple and cost-effective pneumatic extrusion system was designed to 3D print a metal paste containing CuSn15 alloy powders. The metal paste was prepared by manually mixing of CuSn15 powders, carboxymethyl cellulose and distilled water. The printed parts were subsequently dried and sintered at various temperatures and times to study the effects of these parameters on the material properties. Tensile test and scanning electron microscope analysis were conducted to assess the structural integrity and mechanical performance of the samples. Findings The study found that the pneumatic extrusion system enabled the successful 3D printing of CuSn15 bronze alloy parts without the need for complex processes. Increasing sintering temperature led to improved mechanical properties and decreased porosity. Increasing the sintering time at 820 °C led to a reduction in mechanical performance. The study demonstrated that the sintering parameters significantly influence the porosity and mechanical properties of the printed parts. Originality/value This study introduces a novel approach to 3D printing CuSn15 bronze alloy using a pneumatic extrusion system, eliminating the need for traditional filament preparation and solvent/catalytic debinding processes. The research provides new insights into the effect of sintering parameters on the mechanical properties of additively manufactured metal parts. By simplifying the production process, this study offers a low-cost, efficient method for producing complex-shaped metallic components, potentially expanding the applicability of 3D printing in industries such as electronics, marine and mechanical engineering.

Regeneration of Deteriorated Internal Combustion Engine Components used in Thermal Power Plants

The generation of electric power through internal combustion engines plays an important role in the world economy. Exhaust cases and valves are critical engine components and are subjected to high pressures and temperatures. The additive remanufacturing technology of mechanical components that have reached the end of their useful life due to wear, through the L-DED laser directed energy deposition method, proves to be an effective method to obtain spare parts with similar or even superior characteristics to a new part, extending the product life cycle in the circular economy. The process consists of obtaining 3D models through reverse engineering, additive remanufacturing by L-DED and final machining. It was determined through the study that this methodology can be successfully applied to the exhaust boxes and valves of internal combustion engines for electric generation. The results obtained have shown that this remanufacturing method is an effective solution for the recovery of exhaust boxes and valves that have completed their useful life and can be applied to other engine elements, reducing the cost of the spare part compared to a new one and bringing with it important environmental benefits. In reference to the remanufacturing time, it has been determined that the application of the L-DED process in the exhaust boxes and valves is 3943 and 3677 s respectively. In addition to this time, the time used in the initial preparation and final machining must be added; however, the time is substantially less than the manufacturing of a new spare part, which brings with it an increase in the availability of these spare parts to perform scheduled maintenance in the engines for power generation, contributing to improve the efficiency of the national electric system.

Numerical Study on Continuous-Bending-Under-Tension of 3rd Generation Steel

Sheet metal forming is one of the key processes in the manufacturing of parts for several industries, such as automotive, aerospace and packaging. However, it is often constrained by the onset of plastic instability, which limits uniform deformation. To address this challenge, considerable attention has been given to methods that enhance strength, formability, and energy absorption during forming processes. One such method is the continuous-bending-under-tension (CBT) deformation mechanism, which has shown potential in mitigating localized instability during plastic deformation. This study presents a numerical investigation of the CBT process using Abaqus 2017 to evaluate the forces generated in both the CBT equipment and material when processing high-strength materials. The reference material used is the USS CR980XG3™ AHSS, a third-generation, high-strength, high-elongation steel grade with retained austenite (980T/600Y). The study systematically analyzes the effects of key parameters, such as roll diameter, distance between rolls, depth setting, specimen thickness, and the number of deformation cycles, on the evolution of forces during the CBT process. The results demonstrate that both the forces applied by the rolls and those experienced by the specimen are significantly influenced by the distance between rolls, depth setting, and specimen thickness. In contrast, the roll diameters have minimal influence. These findings contribute to the optimization of the CBT process and provide valuable insights for future studies aimed at enhancing the performance and formability of various materials.

Study of the Hibridation of Ablation Casting and Laser Wire Metal Deposition for Aluminum Alloy 5356

The rapidly growing field of metal additive manufacturing (AM) has enabled the fabrication of near-net-shape components with complex 3D structures in a more reliable, productive, and sustainable way compared to any other manufacturing process. The productivity of AM could be significantly increased combining conventional and AM technologies. However, the application at an industrial level requires the validation of the AM process itself and the assurance of the soundness of the junction between the substrate and the deposited metal at a sufficiently rapid metal deposition rate. In this work, the validation of additively manufactured samples of Al-5356 alloy was performed. These were manufactured partially via an ablation casting process and partially via laser metal deposition using a metallic wire (LMwD). The deposited material showed low porosity levels, i.e., below 0.04%, and a small number of lack-of-union defects, which are detrimental to the mechanical properties. In the tensile samples centred at the junction between the ablated and deposited materials, it was found that when the AM part of the sample exhibited no lack-of-union defects, the region manufactured using LMwD showed higher strength than the ablation-cast part. These results suggest that the combination of ablation casting and LMwD is a competitive technique for the manufacturing of Al-5356 alloy parts with complex geometries.

Inline-Acquired Product Point Clouds for Non-Destructive Testing: A Case Study of a Steel Part Manufacturer

Modern vision-based inspection systems are inherently limited by their two-dimensional nature, particularly when inspecting complex product geometries. These systems are often unable to capture critical depth information, leading to challenges in accurately measuring features such as holes, edges, and surfaces with irregular curvature. To address these shortcomings, this study introduces an approach that leverages computer-aided design-oriented three-dimensional point clouds, captured via a laser line triangulation sensor mounted onto a motorized linear guide. This setup facilitates precise surface scanning, extracting complex geometrical features, which are subsequently processed through an AI-based analytical component. Dimensional properties, such as radii and inter-feature distances, are computed using a combination of K-nearest neighbors and least-squares circle fitting algorithms. This approach is validated in the context of steel part manufacturing, where traditional 2D vision-based systems often struggle due to the material’s reflectivity and complex geometries. This system achieves an average accuracy of 95.78% across three different product types, demonstrating robustness and adaptability to varying geometrical configurations. An uncertainty analysis confirms that the measurement deviations remain within acceptable limits, supporting the system’s potential for improving quality control in industrial environments. Thus, the proposed approach may offer a reliable, non-destructive inline testing solution, with the potential to enhance manufacturing efficiency.

Optimization of Mechanical Machining for Heat-Resistance Ta-W Alloy by Using Orthogonal Cutting Method

Tantalum and tantalum alloys, which have superior thermal properties, including a high melting temperature, low specific heat, low thermal conductivity, and high density, are promising candidates for highperformance parts exposed to high temperatures and hazardous environments in aerospace, defense, and other industries. However, those alloys are hard to cut and mechanically machine, and the poor machinability of tantalum alloys has precluded their wide use. This study investigates mechanisms for cutting Ta-10%W alloys using orthogonal cutting methods for precision part manufacturing. During orthogonal cutting processes, the cutting forces are increased dramatically because of the surface folding phenomenon of Ta-W alloys. As a result of experiments and simulation calculations, the tool’s rake angle and depth of cut are critical parameters for controlling the cutting shear angle, which makes a significant difference in chip thicknesses and surface folding phenomenon. Based on the results, about 12 degrees of cutting shear angle is suitable for the mechanical machining of a Ta-W alloy. Additionally, cutting speed may be one of the critical parameters to consider for changing the mechanical responses of Ta-W alloys. With this perspective, the mechanical properties of Ta-W alloys at high strain rates seem to be an important factor in orthogonal cutting. Based on these results, the cutting mechanisms and optimal cutting parameters for Ta-W alloys are discussed.

PARAMETRIC DESIGN AND ADAPTIVE SIZING OF LATTICE STRUCTURES FOR 3D ADDITIVE MANUFACTURING

The present research is developed into the realm of industrial design engineering and additive manufacturing by introducing a parametric design model and adaptive mechanical analysis for a new lattice structure, with a focus on 3D additive manufacturing of complex parts. Focusing on the land-scape of complex parts additive manufacturing, this research proposes geometric parameterization, mechanical adaptive sizing, and numerical validation of a novel lattice structure to optimize the final printed part volume and mass, as well as its structural rigidity. The topology of the lattice structures exhibited pyramidal geometry. Complete parameterization of the lattice structure ensures that the known geometric parameters adjust to defined restrictions, enabling dynamic adaptability based on its load states and boundary conditions, thereby enhancing its mechanical performance. The core methodology integrates analytical automation with mechanical analysis by employing a model based in two-dimensional beam elements. The dimensioning of the lattice structure is analyzed using rigidity models of its sub-elements, providing an evaluation of its global structural behavior after applying the superposition principle. Numerical validation was performed to validate the proposed analytical model. This step ensures that the analytical model defined for dimensioning the lattice structure adjusts to its real mechanical behavior and allows its validation. The present manuscript aims to advance additive manufacturing methodologies by offering a systematic and adaptive approach to lattice structure design. Parametric and adaptive techniques foster new industrial design engineering methods, enabling the dynamic tailoring of lattice structures to meet their mechanical demands and enhance their overall efficiency and performance. Keywords: Computer-Aided Design, Industrial Design, Innovative Design, Additive Manufacturing, FEM Simulations

Integrated manufacturing of heterogeneous-material tillage wear-resisting parts based on selective laser melting

Integrated manufacturing of heterogeneous-material tillage wear-resisting parts based on selective laser melting

Influence of the graphene incorporation on nanostructure and thermal properties of the laser powder bed fusion processed AlSi12 matrix composites

The successful fabrication and implementation of graphene-reinforced aluminum (Al) matrix composites (AMCs) have been obstructed by the undesirable graphene-Al reactions during their casting or inability of complex part manufacturing through powder metallurgy techniques. The emergence of the laser powder bed fusion (L-PBF) process with extremely short melt duration and almost no limitations in terms of the manufacturing of intricate features has renewed the interests for fabrication of graphene-reinforced AMCs. In this study, the influence of graphene incorporation into AlSi12 on L-PBF processability and defect formation is studied. The specific heat capacity, coefficient of thermal expansion, thermal diffusivity and thermal conductivity of composites were compared to those of the monolithic AlSi12 alloy. Microstructure-thermal properties relationship was studied through transmission electron microscopy (TEM), high-resolution TEM (HRTEM), electron backscatter diffraction (EBSD), electron dispersive spectroscopy (EDS) and Raman spectroscopy. This study provides valuable insights into (i) the chance of survival of graphene, (ii) possibility of graphene changing into other forms of carbon, and (iii) graphene-Al reactions during the L-PBF process. It was found that most of the graphene/graphite particles transformed into Al4C3. Among the survived carbon material, it appears they are more disordered than the initial graphene/graphite, though highly ordered ones with almost no defects were also detected. Thermal expansion measurements showed that the coefficient of thermal expansion decreased from 27.5×10-6/˚C for AlSi12 to 25.3×10-6/˚C for AlSi12-0.25Gr and 25.5×10-6/˚C for AlSi12-0.5Gr. Regarding thermal conductivity, in the case of AlSi12-0.5Gr, it either matched or was lower than that of pure AlSi12 within the tested temperature range. In contrast, AlSi12-0.25Gr exhibited higher thermal conductivity than AlSi12 in the temperature range of 150-350 ˚C.

Service Life and Failure Analysis of Nylon, Polycarbonate, and IGUS i180 Polymer Gears Made by Additive Manufacturing

An assessment of different materials for additive manufacturing (AM) of polymer gears is presented in this research. Experimental testing is carried out for three different materials. Two materials are selected as the most common materials used for gears made by additive manufacturing. These materials are nylon and polycarbonate (PC). The third material is IGUS i180, which is a tribological material specially developed for additive manufacturing of parts with demands for high resistance properties such as resistance to friction, wear, and high temperatures which are essential for the long service life of gears. Gears are experimentally tested to determine service life in the form of operating cycles until failure. In addition, the gear temperature is monitored during the experimental testing. Using the value of maximum temperature at the moment of total gear failure at a specific load level enables the categorization of failure type. Different types of gear failures are categorized and presented. Taking into consideration failure type and the service life in the form of operating cycles, the applicability of analyzed materials for specific applications concerning load, speed, and thermal conditions is presented and discussed at the end of the paper. The main goal of this research was to test IGUS i180 material and compare its mechanical and thermal properties with other commonly used materials for gears manufactured by AM, such as nylon (PA6/66) and polycarbonate (PC). IGUS i180 material showed inferior properties concerning gear design in the case of high loads. This research showed that PA6/66 material is still the best solution for polymer gears production using AM, but the applicability of this material, due to temperature constraints, is still quite limited.

Influence of the shape of abrasive soil particles on the regularities of destruction of structural steels during wear

The article presents the results of studying the patterns of destruction and their influence on the wear resistance of structural steels: steel 45, steel 65G and steel 28MnB5 when moving in soils with different abrasive particle shape factors. The phenomenon of the presence of a critical abrasive particle shape factor (CPSF) was established, up to which the wear resistance of steels decreases. In the supercritical region, wear resistance is stabilized, and the differences between its values of the studied steels are significantly reduced. When forming wear resistance, the role of the particle shape factor is to regulate active deformation and fatigue phenomena by means of the level of external force action on the working surface and is realized through the rheological-fatigue parameter, which is controlled by the cyclic viscosity of steel deformation. In this regard, the choice of structural steel grade for the manufacture of machine parts intended for use in soils with different abrasive particle shape factors must be made based on its ranking by the rheological-fatigue parameter. It is shown that in the strength basis of the steel wear mechanism under sliding friction in soils with different particle shape factors, in addition to the resistance to the propagation of axial and radial fatigue cracks in the destructive deformation layer, an important role is played by the resistance to the initiation and propagation of lateral fatigue cracks at its boundary with the plastic-destructive deformation layer, and the mechanical component of the contact interaction is decisive. It is established that under wear in soils with different particle shape factors, the action of the softening process is more effective than the hardening process. In the supercritical region, the intensity of steel softening is significantly reduced due to the increase in the effectiveness of the hardening action due to the dispersion hardening of steel. However, no qualitative changes in the metal wear process are observed

An Insight into Chip and Surface Texture Shaping Under Finish Turning of Powder Steels Infiltrated with Tin Bronze.

The manufacturing of work parts made of powder (sintered) steels is currently widespread in industry, as it provides minimal processing allowances and high dimensional accuracy, as well as the required properties and unconventional chemical composition. At the same time, their low tensile or bending strength must be considered a serious disadvantage. In order to minimize these disadvantages, a number of strengthening technologies are used, among which is the infiltration of porous base materials with metal alloys. In this study, the details of finish turning of sintered iron-graphite-based steel infiltrated with tin bronze with molybdenum disulfide addition are considered. Changes in the shape of chips and their geometric features, as well as the 3D parameters and topography features of the surface machined, are presented after finish turning with AH8015 carbide inserts. The cutting speed (vc) and feed rate (f) were used as variable parameters. It was found that when turning the powder steels under study, the chips took the shape of small fragments or element chips, including segmented chips. For quenching steel, the formation of irregular lamellae was observed and for the initial state, a serrated chip was registered. For the initial state, a reduction in Kb values was observed in the range of the vc of 50-100 m/min and f of 0.05-0.075 mm/rev, and for quenching in the range of 225-250 m/min and 0.05-0.075 mm/rev. Compared to the initial state, for quenching, depending on the cutting parameters, a 14% reduction in the chip spreading ratio Kb or an increase from 2 to 32% was registered. For the initial state and quenching, a decrease in the Sp and Sv parameters was achieved in the range of the vc of 200-250 m/min and f of 0.05-0.075 mm/rev, and there was an increase in the range of 50-150 m/min and 0.125-0.15 mm/rev. Compared to the initial state, an increase in the Sz parameter from 10 to 35% was observed for quenching. On the surfaces machined with vc = 50 m/min and f = 0.05 mm/rev, waves and single significant peaks were observed. On the other hand, vc = 250 m/min and f = 0.15 mm/rev provided classical feed tracks in the form of valleys and irregular ridges on the surfaces machined. The test results can be useful in the design and manufacturing of industrial parts made of powder steels.

Investigation of cutting qualities of AISI304 stainless steel using plasma arc cutting method

Since cutting stainless steels with non-traditional manufacturing processes such as laser beam cutting or water jet cutting is quite costly, machining with the plasma arc cutting (PAC) method, which is generally more economical, has been preferred more frequently in recent years. In this context, the use of PAC method in manufacturing of machine parts, especially in the construction and manufacturing industries, as well as in other industries such as food, automotive and petrochemicals, is increasing day by day. In these sectors, where high corrosion resistance and resistance to acidic environments are required, AISI304 stainless steel is generally preferred as the raw material. In this study, comprehensive literature research on PAC was conducted and the cutting qualities of AISI304 stainless steel plates with 4 and 8 mm thickness were investigated. Nine different types of experiment conditions (E1-E9) were created by the machining parameters (gas pressure: 0.6, 0.7 and 0.8 MPa – cutting speed: 151, 215 and 217 mm/min) determined from other experimental studies in the literature. The lowest average kerf taper value (0.32̊) was obtained on the 4 mm thick plate with a gas pressure of 0.6 MPa and a cutting speed of 151 mm/min, whereas the highest average kerf taper value (2.59̊) was obtained on the 8 mm thick plate where the gas pressure was 0.8 MPa and the cutting speed was 217 mm/min. The results revealed that for both plates, as the cutting speed increases at constant pressure values, the cutting surface roughness values ​​increase. On the other hand, as the cutting speed is constant, the surface roughness decreases as the gas pressure value increases. The plates were cut into 100 mm long straight lines and the bottom surface burr formations and the top surface spatter formations in the PAC method were also examined.

Additive Manufacturing of Watertight ABS Parts and Its Use for Chemical Metal Plating

AbstractOne of the most frequently used polymers in the galvanic industry as well as for Fused Filament Fabrication (FFF) is the terpolymer of acrylonitrile butadiene styrene (ABS). Its surface is etched in chromosulfuric acid to enable the chemical deposition of a metal. The use of chromium (Cr)(VI) compounds is restricted in the European Union (EU) since 2017. A new plating process is proposed here that does not rely on etching. Instead, double bonds on the ABS surface are converted to epoxides, followed by grafting of a polyethylenimine (PEI) to the surface. The so modified plastic is an ideal starting point for metal plating. Printing often leads to the formation of voids between strands and layers, which hinders subsequent wet processing. The plating process introduced here requires high demands on the water tightness of parts. The proposed printing procedure reduces the degree of penetration of water from 50% to less than 0.1% at 2 bar water pressure. The combination of the new printing procedure with the new plating process results in the deposition of industrial relevant nickel (Ni) layers. The cross‐hatch test followed by a peel test exhibits values of zero, pointing to the high adhesion of Ni to ABS.

A APLICAÇÃO DE UMA METODOLOGIA DE SOLUÇÃO DE PROBLEMAS PARA CONTROLE DE QUALIDADE NA INDÚSTRIA MOVELEIRA.ESTUDO DE CASO.

This article contains an analysis of the application of problem-solving tools and methodologies for quality control in the manufacturing of parts for the furniture industry. This analysis is based on widely validated market tools used in an integrated manner, and the study aims to demonstrate the effectiveness of technical control in manufacturing processes. The study provides a comparative analysis over different periods to show the increase in accuracy resulting from strict control of manufacturing methods and production control, as well as the effectiveness of applying improvement tools.

Characterization of laser power on additive manufacturing of heterostructure parts

Abstract In order to meet the demand for low-cost and rapid prototyping of micro-small parts for highly dynamic microsystems, metal additive manufacturing technology has become one of the important means of manufacturing heterogeneous parts. In this paper, the residual stress and deformation generated by the rapid prototyping process of micro-small and complex parts under different laser frequencies are firstly simulated and analyzed, and then in order to check the resistance of the parts to high overload, the densities and hardnesses of the printed parts are experimentally tested. The results show that, on the basis of ensuring that the powder can be fully melted, the lower laser power, the smaller residual stress of the micro-small complex parts, the smaller deformation of the parts caused. The physical energy density also shows a certain correlation to the density and hardness of the specimen, the higher physical energy density, the higher density and hardness of the specimen.

Tool Wear Monitoring in Hard Turning Using Sensor Fusion: An analytical approach

At present, the life expectancy of tool has become a vital aspect in the manufacturing industries, especially where materials with high hardness have more importance. Nowadays hard steel has been widely used for manufacturing of commercial parts in military aircrafts, car systems and hydraulic tools, etc. Manufacturing industries, mainly concentrates on mass production of the products with precision and accuracy. In such cases the continuous machining may weaken the tool causing tool wear which ultimately affects the quality with production rate. To avoid such an unwanted scenario, different tool wear prediction techniques have been introduced which uses cutting force signals or average chip-tool interface temperature or surface roughness signals, etc. According to the literature, different techniques are available for the pre-judgment of the tool wear that shows variation in the accuracy of prediction. Sensor fusion technique can be employed to overcome this problem by combining data from different sensors intelligently to improve the process. Sensor fusion uses this combined data to correct deficiencies of individual sensors and predict the tool wear accurately which compensate for the sudden breakage of the tool in real life applications. In this paper, a new approach of tool wear prediction has been introduced to correlate different available sensor by using sensor fusion technique. Also, a mathematical approach has been derived for the sensor fusion purpose. The experimentation has been carried out using coated carbide inserts on 55 HRC hardened steel.

State of the Art in Incremental Forming: Process Variants, Tooling, Industrial Applications for Complex Part Manufacturing and Sustainability of the Process.

This paper explores the development and application of the incremental forming process, an innovative method for manufacturing complex parts with high flexibility and low tooling costs. The review categorizes three key process variants: Single Point Incremental Forming (SPIF), Two Point Incremental Forming (TPIF), and Incremental Forming with Conjugated Active Plate (IFCAP). This study demonstrates the significant effects of these process variants on part accuracy and material behavior, particularly under varying process conditions. This study identifies critical technological parameters such as tool diameter, feed rate, and vertical step size. The findings also demonstrate the role of optimized toolpaths and lubrication in improving process efficiency. Applications of incremental forming across various industries, including automotive, aerospace, medical, and construction, demonstrate its versatility in prototype production and small-series manufacturing. These results contribute to a deeper understanding of incremental forming, offering practical recommendations to enhance precision, scalability, and material formability, and supporting future innovations and broader industrial applications.

Mechanical characterization of new bi-material generated by additive manufacturing: IZOD test–puncture impact behaviour

PurposeThe purpose of this paper is to characterize a new structural bi-material (scaffold and filler).Design/methodology/approachThe bi-material has been obtained by means of an additive manufacturing system consisting of a fused filament fabrication extruder head and an epoxy resin depositor head. The new bi-material will consist of a thermoplastic material that will serve as the main structure and an epoxy resin that will serve as a filler and adhesion between layers. The creation of this new bi-material will improve the physical–chemical and mechanical properties with respect to the thermoplastic material. This paper will focus on the impact behavior of IZOD and the impact behavior of punctures.FindingsThe new polylactic acid (PLA) and epoxy bi-material allow improvements in toughness and puncture impact resistance compared to the PLA thermoplastic. This increase in toughness is between 20% and 30% depending on the orientation of the print. In the same way, the energy absorbed in the puncture impact test has been increased by 42%–48%.Practical implicationsThe improvement in the impact absorption capacity of this new bi-material makes it ideal for the manufacture of medical parts in which customization, lightness and impact resistance are their main characteristics such as sports protection systems.Originality/valueThe originality of creating parts through additive manufacturing that combines a material generated with cold extrusion, such as epoxy resin and a material generated with hot extrusion, such as thermoplastics, lies in the unique synergy that this mixed and simultaneous technique offers. By uniting these two manufacturing methods, it allows the exploration of new physical and chemical properties in the resulting parts, taking advantage of the individual advantages of each material. This combination opens the door to the creation of components with a wider range of characteristics, from strength and durability to flexibility and temperature resistance, thus offering innovative and versatile solutions for various applications in fields such as engineering, medicine and design.

Electropolishing to Surface Finish of Hastelloy X Manufactured By Laser Powder Bed Fusion

Laser Powder Bed Fusion (LPBF) is a metal additive manufacturing technology (AM) that uses high power laser to melt powder layer by layer to create mechanical parts. LPBF several advantages, including short manufacturing time, freedom to design complex geometries and user-friendly customization. It is widely used in the manufacture of high-value parts in aerospace, automotive and biomedical industries. Due to the nature of the layer-by-layer process, partially melted powder is attached to the as-built part surface during LPBF, resulting in a significant increase in surface roughness. Furthermore, initial surface roughness of final part is different with locations since quantity of powder adhesion varies depending on building angle. Increase of surface roughness due to attached metal powder can cause out of dimensional tolerance that designed. Such dimensional inaccuracy can lead to failure or breakage of the mechanical parts. Therefore, surface post-treatment is essential to reduce surface roughness with minimizing dimensional change. Conventional mechanical and chemical treatments for surface finishing have limitations such as limited tooling range and surface damage due to the use of strong acids and long-time of processing. Electropolishing, based on electrochemical reactions, is suitable for improving the roughness of LPBF manufactured parts with complex geometries. Thickness reduction can be predicted by controlling the applied voltage and processing time. Also, surfaces in contact with the electrolyte is polished without geometric restrictions. Studies have been reported that analyze the change in surface roughness after electropolishing to improve the roughness of alloys manufactured with LPBF. However, for application to real parts, it is necessary to conduct basic research to optimize the electropolishing conditions to obtain satisfactory surface roughness with minimal thickness reduction by considering the effect of dimensional changes during electropolishing. In this study, we electropolished Hastelloy X fabricated by LPBF. Four types of electrolytes were selected for electropolishing. We measured surface roughness and thickness reduction with respect to applied voltage and processing time. With such results, optimized condition to reduce the surface roughness with minimal thickness changes are discussed. Then, these conditions were applied to LPBF specimen with different building angles. Surface roughness and weight changes were measured to compare polishing efficiency to each electrolyte.