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Engineering Science in

Additive Manufacturing

REVIEW ARTICLE
Guidelines for the use and reporting

of experimental statistics in additive
manufacturing: An assessment of current

practices

1
Colin M. Lynch * , Ryan B. Wicker 2,3 , Jorge Mireles 3 , and Rene Villalobos 1
1 Terra Integrated Solutions, Mesa, Arizona, United States of America
2 W.M. Keck Center for 3D Innovation, The University of Texas at El Paso, El Paso, Texas, United
States of America
3 Department of Mechanical and Aerospace Engineering, The University of Texas at El Paso, El
Paso, Texas, United States of America

Abstract

Additive manufacturing (AM) creates three-dimensional objects using various
approaches, typically layer-by-layer. One emerging method is laser-based powder
bed fusion of metals (PBF-LB/M), which uses high-energy lasers to melt metallic
powder into shape. AM processes are influenced by many factors, yet there is no
*Corresponding author: standardized framework for quantifying their effects on final products. This guide
Colin M. Lynch
(cmlynch2@asu.edu) introduces key principles of experimental design and statistics, outlining a roadmap
for conducting rigorous experiments. We review the literature on AM generally and
Citation: Lynch CM, Wicker RB,
Mireles J, Villalobos R. Guidelines PBF-LB/M specifically to assess how well current practices align with standardized
for the use and reporting of methodologies. In addition, we compare the evolution of experimental techniques
experimental statistics in additive in PBF-LB/M to those in a more regulated industry to explore potential cross-
manufacturing: An assessment
of current practices. Eng Sci Add pollination. Our analysis reveals that most studies do not adhere to best practices in
Manuf. 2025;1(4):025340021. experimental design and statistical analysis. For example, randomization of run order
doi: 10.36922/ESAM025340021 is rarely mentioned, and statistical model assumptions are often unchecked. Even in
Received: August 19, 2025 tightly regulated fields, experimental designs and statistical methods remain basic
and lack sophistication. To improve research quality, we provide recommendations
1st revised: September 18, 2025
for establishing standardized experimental and reporting practices in AM.
2nd revised: September 22, 2025
Accepted: September 24, 2025 Keywords: Design of experiments; Response surface methodology; Additive
Published online: November 14, manufacturing and 3D printing; Laser-based powder bed fusion of metals; Experimental
2025 statistics
Copyright: © 2025 Author(s).
This is an Open-Access article
distributed under the terms of the
Creative Commons Attribution
License, permitting distribution, 1. Introduction
and reproduction in any medium,
provided the original work is Over the past few decades, additive manufacturing (AM) has undergone tremendous
properly cited. evolution, transitioning from research laboratories to widespread industrial adoption. This
1
Publisher’s Note: AccScience evolution depends strongly on the vast experimental effort to discover new technologies,
Publishing remains neutral with materials, and processes. Despite these advancements, AM can still be considered to
2
regard to jurisdictional claims in
published maps and institutional be in its infancy, as further work needs to be done to ensure that manufactured parts
affiliations. have performance characteristics equivalent to—or better than—parts manufactured

Volume 1 Issue 4 (2025) 1 doi: 10.36922/ESAM025340021