Suppressing the deformation of as-built parts by optimizing the structure of boss bottom in material extrusion of metals

Compared to other metal additive manufacturing technologies, material extrusion (ME) of metals offer several advantages, including low investment cost, safety, simpleness and so on. However, part deformation caused by material shrinkage will reduce its productivity. To address this issue, a method was provided to suppress the deformation by optimizing the boss bottom. The stress field of the model was analyzed using finite element model (FEM), and self-made equipment was used to print the as-built part using 17-4PH stainless steel powder and polymer. The result revealed that the bottom structure could effectively change the stress field of the model and prevent deformation. The optimized structure of the boss bottom could widen the process window and save up to 61.82 % of materials. In conclusion, it provided a new perspective for forming as-built parts without deformation in ME of metals.