Subtractive Manufacturing Research Articles

LDED-based additive-subtractive hybrid manufacturing of Inconel 718 superalloy: evolution of microstructure and residual stress

ABSTRACT The development of additive-subtractive hybrid manufacturing (ASHM) offers a near-perfect solution for the integrated preparation of complex structural components. In this study, we prepared additive manufacturing (AM), ASHM-fabricated Inconel 718 (IN718) superalloy based on laser-directed energy deposition (LDED), including two subtractive manufacturing (SM) situations, i.e. milling after cooling (room temperature SM) and immediately milling after AM (high-temperature SM). The evolution of microstructure, residual stress and milling forces for IN718 during a complete ASHM process (including AM and subsequent SM) were explored by experiments, finite element and molecular dynamics simulation. The SM process induces gradient plastic deformation on the sample surface, which led to the formation of nano-grains, low-angle grain boundaries and residual compressive stress. Owing to the higher internal temperatures present at SM, the thermal softening effect results in lower milling forces being subjected to high-temperature SM sample. Also, the dynamic recovery results in lesser nano-grains, low-angle grain boundaries and residual compressive stress in high-temperature SM sample. Thus, SM immediately after AM has a lower degree of plastic deformation on the sample surface compared to room temperature SM, and shows advantages in the preparation of difficult-to-machine materials. Highlights Inconel 718 (IN718) superalloy was prepared by LDED-based additive-subtractive hybrid manufacturing (ASHM). The evolution of microstructure, residual stress and nano-hardness for IN718 during ASHM were investigated. Subtractive manufacturing process of ASHM introduces nano-grains and residual compressive stress. Thermal softening effects and dynamic recovery affect the plastic deformation degree of ASHM-fabricated IN718.

In Vitro Comparison of Surface Characteristics and Bacterial Adhesion in Composite Resin-Based Materials for Additive, Subtractive, and Conventional Manufacturing.

This study aims to compare the surface roughness (SR), contact angle (CA), surface free energy (SFE), and bacterial adhesion of resin-based materials used in additive, subtractive, and conventional manufacturing techniques. This study involved four groups of 23 specimens: Indirect conventional resin composite (ICRC), subtractively manufactured resin composite (SMRC), additively manufactured resin composite (AMRC), and soda-lime-silica glass (SLSG). One specimen per group was analyzed by Energy Dispersive X-ray Spectroscopy (EDS) before polishing. Following the polishing procedure, SR, CA, and SFE were measured. The sterilized specimens were divided into two subgroups for Streptococcus mutans and Streptococcus mitis adhesion. One randomly selected specimen from each group was also reserved for visualization of bacterial adhesion using Scanning Electron Microscopy (SEM), and bacterial adhesion was quantified in the remaining specimens (n=10). Data for SR, CA, SFE, and bacterial adhesion were analyzed using one-way ANOVA, Tukey post-hoc tests, and Pearson correlation (α = .05). Among the resin groups, the ICRC group had the lowest SR values (P < .001). The higher CA was observed in the SMRC group than AMRC (P = .016). AMRC displayed significantly lower S. mitis adhesion compared to ICRC and SMRC (P < .001 and P = .003, respectively). A positive correlation was found between SR and S.mutans adhesion (R = .455, P < .003). Resin materials designed for different manufacturing techniques exhibited diverse surface characteristics. Nevertheless, the 3D printable permanent resin demonstrated comparable S. mutans adhesion to that of ICRC and SMRC.

FPGA-Based Sensors for Distributed Digital Manufacturing Systems: A State-of-the-Art Review.

The combination of distributed digital factories (D2Fs) with sustainable practices has been proposed as a revolutionary technique in modern manufacturing. This review paper explores the convergence of D2F with innovative sensor technology, concentrating on the role of Field Programmable Gate Arrays (FPGAs) in promoting this paradigm. A D2F is defined as an integrated framework where digital twins (DTs), sensors, laser additive manufacturing (laser-AM), and subtractive manufacturing (SM) work in synchronization. Here, DTs serve as a virtual replica of physical machines, allowing accurate monitoring and control of a given manufacturing process. These DTs are supplemented by sensors, providing near-real-time data to assure the effectiveness of the manufacturing processes. FPGAs, identified for their re-programmability, reduced power usage, and enhanced processing compared to traditional processors, are increasingly being used to develop near-real-time monitoring systems within manufacturing networks. This review paper identifies the recent expansions in FPGA-based sensors and their exploration within the D2Fs operations. The primary topics incorporate the deployment of eco-efficient data management and near-real-time monitoring, targeted at lowering waste and optimizing resources. The review paper also identifies the future research directions in this field. By incorporating advanced sensors, DTs, laser-AM, and SM processes, this review emphasizes a path toward more sustainable and resilient D2Fs operations.

Damage characterization of AlSi10Mg plates subjected to rigid impacts up to 300 m/s: comparison between subtractive and additive manufacturing

Mechanical structures built using the additive manufacturing (AM) process are generating significant interest due to their ability to design structural components with complex geometries. Indeed, additive processes, by adding material layer by layer, enables the creation of geometries that would be unfeasible using standard processes. However, while mechanical tests have extensively validated the use of conventional processes, the characterization of parts generated by less conventional processes, such as additive manufacturing, remains open to discussion. Specifically, will a part manufactured by AM meet the specifications in terms of mechanical strength? This paper contributes to answering this question by comparing identical AlSi10Mg plates manufactured using the AM process with a LASER powder bed fusion (L-PBF) machine (additive) and by conventional subtractive process (SM), subjected to high-velocity impacts. The impacts have been conducted on additive and subtractive 70*150*2 mm plates up to 300 m/s.” Based on measurements of projectile impact and residual velocities, as well as the study of deformation profiles of the different plates, the damage domains were identified. These tests highlighted significant differences between the different processes.

Environmental comparison of opposing manufacturing strategies at changing of energy sources, EoL approaches and shape peculiarity for an automotive component

ABSTRACT Additive manufacturing (AM) has been considered as an alternative to the conventional Subtractive Manufacturing (SM) technique. This research aimed at performing a life cycle assessment (LCA) of an automotive component manufactured by both the proposed manufacturing techniques at changing the volume ratio between the final shape and the initial enveloping billet. The study quantified the required cumulative energy demands (CED) and specific Midpoint and Endpoint indicators. The advantage of SM as a process less environmentally impacting than AM has been observed at least up to a billet mass reduction of 90%. This result is consistent only if the generated chip in the SM process is recycled correctly, otherwise the material’s energy incidence for SM is markedly impacting with a break-even point in between 40% and 80% of the billet’s material reduction. Furthermore, at the growth of the manufacturing phase, the environmental impactful of the production site’ choice starts to be more relevant due to the peculiarity of the countries’ energy sources. Looking at the CED, the environmental impact of petroleum sources is more relevant if compared to nuclear and/or hydroelectric energy sources. Nuclear energy, instead, loses its environmental competitiveness if specific midpoint and endpoint indicators are taken into account.

A Comparison of Internal, Marginal, and Incisal Gaps in Zirconia Laminates Fabricated Using Subtractive Manufacturing and 3D Printing Methods.

DLP printing is a new method for producing zirconia laminates that ensure clinically acceptable gaps in the internal, marginal, and incisal regions. A typical model of a central maxillary incisor was prepped by a dentist and scanned. The laminate was designed using CAD software version 2023. The laminates were fabricated using a milling machine (LSM group) and a DLP printer (LAM group) (N = 20). The gap was evaluated using the silicone replica method at designated measurement points. Statistical analyses were performed. The Shapiro-Wilk and Kolmogorov-Smirnov tests indicated a non-normal distribution, and the Mann-Whitney test was used. The LSM group had wider gaps than the LAM group except at point E (59.5 µm). The LAM group had wider gaps than the LSM group, except at points H (51.70 µm). No significant differences were observed between the LSM and LAM groups at any of the labiolingual measurement points. In the mesiodistal plane, a significant difference was observed between the two groups at point G, which was adjacent to the mesial side (p < 0.05). The results of this study indicate that DLP printing offers an innovative approach for producing zirconia laminates, as the incisal, internal, and marginal gaps are within clinically acceptable ranges compared with the AM method.

Effect of silane-doped argon shielding gases for gas metal arc welding of S355

The welding of steel grades relies primarily on the interaction of the weld metal with doped oxygen components of the shielding gas. This mainly serves to decrease the viscosity and reduce the surface tension of the melt in order to achieve an adjusted material transition. Interference with the ambient atmosphere is undesirable in this context. In order to prevent material-related changes in the microstructure, slag initiators are admixed which promote the precipitation of low-density oxides on the weld seam surface. Manufacturing technology is increasingly striving to eliminate the interaction of atmospheric oxygen in the production process. It is primarily intended to counteract the negative effects of oxygen during manufacturing. For this objective, silane-doped gases for subtractive manufacturing processes and additive manufacturing via the PBF-LB/M process have been considered. Small amounts of silane in conventional inert shielding gases allow partial pressures of oxygen that are comparable to a high vacuum. In the scope of this publication on investigations for welding applications, blind welds on S355 substrate plates were performed using G3Si1 filler material. In addition to the recommended M21, an argon shielding gas with 1.5% silane doping and argon 4.6 are applied for welding. Apart from the observation of the resulting energy input, the weld seams are metallographically characterized. For this purpose, the formation of silicates on the weld seam surface and the development of the weld seam within the base material are investigated. The volume of the weld seam is reduced as a result of the silane doping compared to the M21 application. The composition of the weld metal is significantly influenced by the silane content, leading to an increased manganese content in particular. The silane doping results in an intensified formation of an acicular bainitic structure and an accompanying hardening within the weld metal.

Laser Powder Bed Fusion Manufactured Hydrostatic Journal Bearings for Turbomachinery: Design and Measurements of Static Load Testing With Air, Water, and Liquid Nitrogen

Abstract Modern turbomachinery demands simplified components and compact shaft support systems. This study introduces novel hydrostatic journal bearings incorporating multiple tilting pads and fluid feeding features, which are manufactured with Direct Metal Laser Melting (DMLM) technology, an advanced laser powder bed fusion manufacturing process. Two test bearings, fabricated by fusing extremely thin layers of Inconel 718 powder, incorporate fluid external feed pressurization features without the need for recesses. One test bearing features unique internal feeding hole configurations, which combine multiple holes with an angled injection feature, while the other test bearing includes distinctive porous layers on the bearing pad surfaces. This paper provides a comprehensive overview of the design, fabrication process, and static load characteristic measurements of these innovative bearings. A simple static load test rig is used to measure the flow rate, temperature, and stiffnesses of the test bearings while supplying compressed air, water, and liquid nitrogen with increasing static loads. The performance of these bearings is compared with counterparts produced using computer numerical control (CNC) machining, a conventional subtractive manufacturing process. In general, the bearings lubricated with liquid nitrogen exhibit a higher load capacity compared to those lubricated with air. This study confirms the static load performance of metal three-dimensional printed hydrostatic journal bearings, marking a significant advancement in the application of additive manufacturing for turbomachinery bearings. The findings offer valuable insights into the potential of additive manufacturing in producing bearings for extreme operating conditions and various lubricants.

Research Progress in Shape-Control Methods for Wire-Arc-Directed Energy Deposition.

Wire-arc-directed energy deposition (WA-DED) stands out as a highly efficient and adaptable technology for near-net-shaped metal manufacturing, with promising application prospects. However, the shape control capability of this technology is relatively underdeveloped, necessitating further refinement. This review summarizes the latest advancements in the shape control of WA-DED technology, covering four pivotal areas: the regulation of various process parameters, optimization of the deposition paths, control through auxiliary energy and mechanical fields, and synergy between additive and subtractive manufacturing approaches. Firstly, this review delves into the influence of deposition current, travel speed, wire feed speed and other parameters on the forming accuracy of additively manufactured parts. This section introduces control strategies such as heat input and dissipation management, torch orientation adjustment, droplet behavior regulation, and inter-layer temperature optimization. Secondly, various types of overlap models and techniques for designing overall deposition paths, which are essential for achieving desired part geometries, are summarized. Next, auxiliary fields for shape and property control, including magnetic field, ultrasonic field, and mechanical field, are discussed. Finally, the application of milling as a subtractive post-process is discussed, and the state-of-the-art integrated additive-subtractive manufacturing method is introduced. This comprehensive review is designed to provide valuable insights for researchers who are committed to addressing the forming defects associated with this process.

Surface properties and biofilm formation on resins for subtractively and additively manufactured fixed dental prostheses aged in artificial saliva: Effect of material type and surface finishing

Statement of problemAdditive manufacturing (AM) and subtractive manufacturing (SM) have been widely used for fabricating resin-based fixed dental prostheses. However, studies on the effects of material type (AM or SM resin) and surface finishing (polishing or glazing) on the surface properties and biofilm formation are lacking. PurposeThe purpose of this in vitro study was to investigate the effects of material type and surface finishing on the surface roughness, wettability, protein adsorption, and microbial adhesion of the AM and SM resins marketed for fixed restorations under artificial saliva-aged conditions. Material and methodsDisk-shaped specimens (∅10×2 mm) were fabricated using 3 types of resins: AM composite resin with fillers (AMC), AM resin without fillers (AMU), and SM composite resin with fillers (SMC). Each resin group was divided into 2 subgroups based on surface finishing: polished (P) and glazed (G). Therefore, 3 polished surface groups (AMCP, AMUP, and SMCP) and 3 glazed surface groups (AMCG, AMUG, and SMCG) were prepared. Specimens were then categorized according to aging condition in artificial saliva. Surface roughness (Ra and Sa), contact angle, surface free energy (SFE), protein adsorption, and microbial adhesion were measured. The data were analyzed using a nonparametric factorial analysis of variances and post hoc tests with Bonferroni correction (α=.05). ResultsWhen nonaged, significant interactions between material type and surface finishing were detected for Ra, contact angle, SFE, protein adsorption, and microbial adhesion (P≤.008). AMCP showed higher Ra and microbial adhesion than AMUP and SMCP, and higher contact angle and protein adsorption than SMCP (P<.001). AMCG had lower SFE than AMUG (P=.005) and higher bacterial adhesion than SMCG (P<.001). AMC had higher Sa than AMU and SMC (P≤.006). When aged, significant interactions between material type and surface finishing were detected for Ra, Sa, protein adsorption, and microbial adhesion (P≤.026). The contact angle and SFE were significantly affected only by the material type (P≤.001), as AMC exhibited higher wettability than SMC (P≤.004). AMCP had higher Ra and microbial adhesion than AMUP and SMCP (P≤.003). AMCP had higher Sa and protein adsorption than SMCP (P≤.004). AMCG showed lower Ra and higher protein adsorption than AMUG (P≤.001). ConclusionsBoth material type and surface finishing significantly affected surface properties and biofilm formation. AMCP exhibited higher surface roughness, protein adsorption, and microbial adhesion compared with SMCP. Glazing may reduce the differences in surface-biofilm interactions between AMC and SMC.

Laser-Assisted Micropatterned 3D Printed Scaffolds with Customizable Surface Topography and Porosity for Modulation of Cell Function.

The dynamic interaction between cells and their substrate is a cornerstone of biomaterial-based tissue regeneration focused on unraveling the complex factors that govern this crucial relationship. A key challenge is translating physical cues from 2D to 3D due to limitations in current biofabrication techniques. In response, this study introduces an innovative approach that combines additive and subtractive manufacturing for precise surface patterning of 3D printed scaffolds. Using poly(𝜀-caprolactone) as the scaffold material, polymeric fibers are 3D printed and subsequently laser-engraved with femtosecond laser to precisely create controlled microtopographies, including microgrooves (10 and 80µm in width) and micropits (25µm in diameter). Testing shows that the process does not compromise the mechanical properties of the fibers, which is critical for structural applications in tissue engineering. Human mesenchymal stem cells are used to investigate the effects of these topographical features on cell behavior. The 10 µm wide microgrooves notably enhance cell attachment, with cells aligning in elongated forms along the grooves, while micropits and unpatterned surfaces promote polygonal cell shapes. This combined approach demonstrates that precisely engineered microtopographies on 3D printed scaffolds can better mimic the natural extracellular matrix, improving cellular responses and offering a promising strategy for advancing tissue regeneration.

Additive and subtractive hybrid manufacturing assisted by femtosecond adaptive optics

Advanced micro–nano devices commonly require precise three-dimensional (3D) fabrication solutions for pre-designing and integrating 0D to 3D configurations. The additive–subtractive hybrid manufacturing strategy dominated by femtosecond laser direct writing has become an increasingly interesting technical route for material processing. In this study, a novel approach termed femtosecond adaptive optics-assisted hybrid manufacturing was proposed, which integrates subtractive (femtosecond laser ablation) and additive (two-photon polymerization) fabrication. In this hybrid manufacturing method, the introduction of adaptive optics offers parallel direct writing and wide-area material processing capabilities. To demonstrate the validity of the hybrid approach, on-chip surface plasmon polariton waveguides with strong sub-wavelength field confinement and enhanced functionality were successfully fabricated. In comparison with the terahertz-wave devices fabricated based on the focused ion beam technique, the functional tests in terahertz near-field microscopy show a rival performance fabricated with our hybrid approach. Besides, our cost-effective solution also dramatically reduces the fabricating time of excitation regions by a factor &gt;16. Our work provides a new inspiration in integrated photonics.

Influence of the Cooling Temperature on the Surface Quality in Integrated Additive and Subtractive Manufacturing of Aluminum Alloy.

The surface quality of parts processed by laser additive manufacturing, especially laser-based directed energy deposition (LDED), makes it difficult to meet actual use requirements. In addition, defects generated during the long-term additive manufacturing process need to be removed in time. Therefore, laser additive and subtractive manufacturing is of great significance for additive manufacturing. The main difference between laser additive-subtractive manufacturing and pure subtraction is that a cooling temperature is required due to the laser process. Therefore, this work studies the temperature variation regularity during LDED and the milling processes, as well as the surface roughness, cross-sectional microstructure, and tool wear under different cooling temperatures for milling. The results show that there is a "turning point temperature" in LDED, and the value of the turning point temperature gradually increases with heat accumulation, which affects the initial temperature of the subtractive manufacturing. When subtracting, a high initial temperature improves surface quality and reduces tool wear, but an excessively high temperature will cause the aluminum alloy to adhere to the tool. Then, the smear metal is difficult to effectively remove, deteriorates the milling quality, and aggravates tool wear. It is found that the higher the cooling temperature generated, the wider the thermally insulated shear band. The insulated shear band may affect the quality of the additive and subtractive manufacturing. Finally, it is determined that the milling temperature of aluminum alloy in this work condition is about 100 °C.

A geometrically scalable method for manufacturing high quality factor mechanical resonators.

We present what we believe to be a novel, geometrically scalable manufacturing method for creating compact, low-resonance frequency, and high quality factor fused silica resonators. These resonators are intended to be used in inertial sensors for measuring external disturbances of sensitive physics experiments. The novel method uses direct bonding and chemical-mechanical polishing (CMP) in order to overcome the limitations of current subtractive manufacturing methods, which face prohibitive cost and complexity as material removal increases, inherently restricting the design flexibility of the resonator. We demonstrate a prototype with a test mass of only 3 g that reaches a quality factor of Q = 118 000 ± 400 at a resonance frequency of below 20 Hz. This advancement is particularly significant for future gravitational wave observatories, such as the Einstein Telescope.

Intaglio surface of CNC milled versus 3D printed maxillary complete denture bases – An in vitro investigation of the accuracy of seven systems

ObjectivesThe accuracy of the intaglio surface of maxillary complete dentures produced with a variety of digital manufacturing systems have been comprehensively investigated, however, not for multiple systems in the same study. This in vitro study endeavors to measure and compare the accuracy of the intaglio surface of maxillary complete denture bases constructed with different photopolymerization-based 3D printing and CNC milling systems. Materials and MethodsTwo subtractive manufacturing machines and five additive manufacturing machines were used to manufacture a maxillary denture bases (n = 10) for analysis. The samples were stored in artificial saliva at 37 °C for 7 days to mimic intraoral use before they were air dried for 5 min, and then scanned with an E3 dental laboratory scanner to generate STL files. A 3D metrology software program was used to analyze the data against the original CAD design. Statistical differences were determined with 1-way analysis of variance (ANOVA) and the Kruskal Wallis test (α=0.05). Color deviation heat maps were used to interpret areas of clinical significance. ResultsThe results indicated that the subtractive manufacturing method delivers the truest and most precise intaglio surface of maxillary complete denture bases. The additive manufacturing technique delivers less true and less precise results with inconsistency observed between the different systems as opposed to the subtractive manufacturing groups which showed no significant differences. ConclusionsWhen manufacturing a complete maxillary denture base subtractive manufacturing will deliver the most consistent and true results.

Continuous Toolpath Optimization for Simultaneous Four‐Axis Subtractive Manufacturing

Continuous Toolpath Optimization for Simultaneous Four‐Axis Subtractive Manufacturing

The Effect of Gastric Acid and Material Type on the Surface Roughness of Additive and Subtractive Manufacturing Resins.

The aim of this study is to examine the effect of gastric acid on the surface roughness of additive and subtractive manufacturing resin. In this study, two subtractive manufacturing CAD-CAM resin nanoceramic (CerasmartTM270 (CS), LavaTM Ultimate (LU)) and two additive manufacturing 3D printing permanent resin (VarseoSmile Crownplus (VSP), Crowntec (CT)) was used. CS and LU samples were turned into 10 mm diameter cylinders with a scraper and cut into 2 mm slices on the cutting device. CT and VSP samples were produced on a 3D printer (2mm thickness-10mm diameter) (n:15). All samples were exposed to a cycle of 60 seconds of gastric acid, 5 seconds of distilled water, and 30 minutes of artificial saliva, 6 times a day for 10 days. Surface roughness mean (Ra) and depth (Rz) was measured with a contact profilometer at baseline and after gastric acid cycling. Data were analyzed using SPSS (22.0), One way ANOVA, post-hoc Tukey's and Independent-t test (p <.05). Ra-Rz values of CT and VSP were significantly higher than CS and LU at baseline and after the gastric acid cycle (p <.05). After the gastric acid cycle, the Ra-Rz values of all materials increased significantly compared to the baseline (p <.05) but the Ra values of all materials were at a clinically acceptable level (<0.2µm). Although additive manufacturing 3D printing permanent resins offered higher roughness values, they weren't at a clinically unacceptable level. Therefore, they can be an alternative to subtractive manufacturing CAD-CAM resin nanoceramics.

Study on hybrid 3D printing and milling process for customized polyether-ether-ketone components.

Polyether-ether-ketone (PEEK) has been widely applied in various fields due to its excellent mechanical properties and biocompatibility. The efficient and high-quality customized manufacturing of PEEK components are investigated in this study by the hybrid 3D printing and milling process. At first, the alternating hybrid process is selected and verified by comparing two typical hybrid process categories and conducting experiments, respectively. Second, a set of procedures are designed to automate the engineering application of the hybrid process trying to avoid the disadvantages of manual programing. Then, considering the tool length and possible interferences during the hybrid process, a model segmentation algorithm, namely, the exchange principle of avoiding interference (EPAI) is proposed. Based on the introduced EPAI and the programing language Python, the additive and subtractive hybrid manufacturing (ASHM) data processing procedure is proposed and realized by post-processing of the conventional 3D printing codes. Finally, the feasibility experiments have been conducted. The experimental results verify the hybrid manufacturing process in the fabrication of parts with complex internal features. The surface roughness Ra and dimensional error L of the parts have been reduced by 75.5% and 85.2%, respectively, while the shear strength τ has been increased by 14.1%. Compared with conventional milling process, the material consumption is reduced by 48.7%.

Toolpath and Tool Design Innovations in Deformation Machining for Superior AA-7075 T6 Fins

Abstract A hybrid manufacturing process, deformation machining (DM) combines subtractive manufacturing with incremental forming. Monolithic components with complex profiles are created through the hybridization of manufacturing technologies, which also reduces the wastage of raw materials. The properties of geometry and surface quality of the fin made from the aluminum alloy Al-7075 T6 using the DM process’s bending mode was examined in this research, as were the effects of various approaches, toolpath methods, and tool design. To achieve the desired shape for the machined fin, various combinations of arcuate and slanting fin toolpath techniques were explored utilizing both top-down and bottom-up methods. The bottom-up method and the arcuate toolpath strategy were used to investigate various tool profiles. Using the best combination of toolpath strategy and tool profile, named as the T3 tool profile, which has a 0.6 mm nose radius and a circular sector, bottom-to-top (BTT)technique, and arcuate toolpath method, components with better geometrical features and surface roughness (SR) were produced. The analysis of the forming force in the bending approach of the DM progression was further carried out using this optimal combination.

On morphology and roughness of upskin surfaces in laser powder-bed fusion additive manufacturing – Contouring strategy effects

The surface quality of inclined parts made by Laser powder-bed fusion (L-PBF) additive manufacturing is inferior to those made by conventional formative and subtractive manufacturing techniques. The inherited step edges formed during such layer-by-layer fabrications and partially melted or non-melted particles attached to the newly formed surface are the major causes of poor surface finish of L-PBF parts. This study is a part of a research framework, in which the effects of different contouring strategies and scan parameters on the surface morphology of inclined parts are investigated by both experimental and numerical methods. In particular, the effect of two different contour scan strategies, namely pre-contouring and post-contouring, on the upskin surface roughness of 30⁰ inclined parts is analyzed. The inclined specimens were fabricated with Ti6Al4V powder using an EOS M270 system and the upskin surfaces were measured by a white light interferometer. In addition, a multi-track multi-layer numerical approach using coupled discrete element method and thermo-fluid simulation was also performed to understand the inclined surface formation in L-PBF.The findings show that the pre-contouring strategy with high linear energy density (LED) (0.4 J/mm) results in average surface roughness (Sa) as low as 7.43 µm, whereas the lowest LED (0.05 J/mm) resulted in the highest Sa of 33.74 µm. Larger melt pool dimensions were obtained in the high LED pre-contouring simulations, which indicates a better material fusion resulting in a good surface finish. The numerical simulation showed that the upskin surface roughness is also affected by the raster scan, if the raster scanning LED is higher than that of pre-contour scans. For the post-contouring strategy studied, higher and lower LEDs were used in inner and outer contour scanning, respectively. It is indicated that the inner contour scanning with a high LED reduces the surface roughness because of a larger melt pool size, irrespective of outer contour scanning. The lowest Sa obtained was 8.24 µm for the highest LED inner contour (0.05 J/mm) case and the highest Sa was 19.95 µm, for the parts made with the lowest LED inner contour scan (0.075 J/mm) strategy. The coupled discrete-element and thermo-fluid-based simulations offer insights into the sloped surface formation and the results supported the experimental findings in qualitative manner.