Optimization of process parameters for support-free inclined wall printing and their effect on the mechanical properties of 316L parts produced by slm

The Selective Laser Melting (SLM) technique has become popular because it enables the manufacture of intricate metal components while maintaining high design freedom. The surface quality of downskin regions remains problematic when printing overhanging structures at an angle of less than 45°. These regions exhibit poor surface quality because insufficient heat dissipation produces excessive roughness and partially fused powder adhesion that leads to defect formation. Surface imperfections function as stress concentrators which reduce mechanical properties and fatigue resistance. In the energy industry, the issue takes on increased importance because component integrity and durability are fundamental requirements. The research focuses on finding optimal process parameters to improve the surface quality of the down skin of SLM-produced 316L stainless steel parts. The parametric study systematically adjusted laser power and hatch spacing, along with other crucial parameters, to achieve reduced surface roughness and stable processing conditions. Researchers tested the optimized parameters’ impact on room-temperature mechanical properties like tensile strength. The experimental results focus carefully on the relationship between reduced skin surface roughness, tensile strength, and fatigue life. They show how enhanced surface quality can delay the start of fatigue cracking and extend the life of components. This study advances SLM process optimization methods in structural applications where tensile strength and surface quality are critical design factors, particularly in the energy industry.