Page 79 - MSAM-4-2

Materials Science in

Additive Manufacturing

ORIGINAL RESEARCH ARTICLE
Technology overview and investigation of

the quality of a 3D-printed maraging steel
demonstration part

César M. A. Vasques * , Adélio M. S. Cavadas 1 , and João C. C. Abrantes 1
1,2
1 proMetheus, Higher School of Technology and Management, Polytechnic Institute of Viana do Castelo
(IPVC), Rua Escola Industrial e Comercial de Nun’ Álvares, 4900-347, Viana do Castelo, Portugal
2 Center for Mechanical Technology and Automation (TEMA), Department of Mechanical Engineering,
University of Aveiro, Campus Universitário de Santiago, 3810-193 Aveiro, Portugal

Abstract

Additive manufacturing (AM) has gained significant traction in the production
of high-performance metallic components, yet concerns persist regarding the
consistency of powder materials and the mechanical properties of 3D-printed parts.
This study addresses these challenges through a detailed analysis of a maraging
steel part manufactured using laser powder bed fusion. The demonstration part
was evaluated for geometric accuracy, surface roughness, chemical composition,
microstructure, and mechanical properties, including hardness and density. The
findings revealed that 3D-printed maraging steel components can achieve high
levels of dimensional precision and mechanical integrity, making them suitable for
*Corresponding author:
César M. A. Vasques demanding applications. Despite these promising results, the study highlighted the
(cmavasques@ua.pt) need for improved powder quality control and accurate composition measurement
Citation: Vasques CMA, to ensure the consistent production of reliable parts. The non-destructive hardness
Cavadas AMS, Abrantes JCC. testing method applied in this study proved effective for predicting tensile strength,
Technology overview and offering a streamlined approach to quality assurance. These results contribute to
investigation of the quality of
a 3D-printed maraging steel a growing body of research and knowledge supporting the adoption of AM for
demonstration part. Mater Sci Add producing critical mechanical components, while underscoring the need for further
Manuf. 2025;4(2):025040002. investigation into quality assurance and standardized non-destructive testing
doi: 10.36922/MSAM025040002 procedures for high-performance metal AM parts.
Received: January 21, 2025
Revised: March 3, 2025 Keywords: 3D printing; Additive manufacturing; Laser powder bed fusion; Steel 1.2709;
Accepted: March 6, 2025 Maraging steel; Quality analysis; Mechanical properties
Published online: April 8, 2025
Copyright: © 2025 Author(s).
This is an Open-Access article 1. Introduction
distributed under the terms of the
Creative Commons Attribution Additive manufacturing (AM), particularly through laser powder bed fusion (LPBF),
License, permitting distribution,
and reproduction in any medium, commonly also referred to as selective laser melting (SLM), has become a transformative
provided the original work is force in modern manufacturing. This technology allows for the creation of customized,
properly cited. high-performance mechanical components with intricate and complex geometries.
Publisher’s Note: AccScience Unlike traditional subtractive methods such as turning or milling, where material is
Publishing remains neutral with removed to shape a part, AM builds components layer by layer. This unique process
regard to jurisdictional claims in
published maps and institutional is guided by a 3D model, and with the advent of “design for additive manufacturing”,
affiliations. engineers now design parts with both the capabilities and constraints of AM in mind. 1

Volume 4 Issue 2 (2025) 1 doi: 10.36922/MSAM025040002