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Copyright © The Author(s) 2022. To increase industrial adoption, part qualification and certification of the additive manufacturing (AM) process are crucial through geometric benchmarking as well as optimising the properties and process parameters. However, an extensive research gap remains concerning the geometric dimensioning and tolerancing (GD&T) of AM parts. This paper presents a review on the state-of-art GD&T benchmarking of powder bed fusion techniques enabling complex geometrical features like lattices. The study found a lack of design guidelines and standardised measurement techniques for lattice features and profiles. European Union, through a project call “H2020-WIDESPREAD-05-2017-Twinning” Grant number 810708 and project name Increasing Excellence on Advanced Additive Manufacturing (INEX-ADAM).

Understanding the influence of process parameters and defect structure on the properties of parts produced via laser powder bed fusion (L-PBF) is a fundamental step towards the broader use of additive manufacturing technologies in critical applications. Furthermore, the ability to predict mechanical properties by simply considering information on the process parameters and defects observed via X-ray computer tomography (XCT) allows one to avoid expensive destructive testing, provide an in-depth understanding of the process quality and represents a viable solution towards process optimisation. Most of the previous works showed that energy density could be used as an excellent synthetic indicator to predict the mechanical properties of parts produced by L-PBF. This paper explores the effect of different energy density levels on the tensile properties of 316L stainless steel parts produced by L-PBF. Different from previous works in the literature, the same level of energy density is obtained considering various combinations of process parameters (speed, power and hatch distance). While energy density is shown to be a good synthetic indicator for predicting ultimate tensile strength (UTS) and yield strength (YS), a different behaviour is observed for elongation. Elongation shows a significant variability even when samples are produced at the same level of energy density, which contrasts with results obtained for UTS and YS. Synthetic indices representing the porosity structure are shown to be quite significant for predicting elongation even when the optimal energy density is considered. By combining process parameters with porosity structure, we show that almost a full prediction of the tensile properties can be achieved, paving the way for a significant reduction in expensive destructive tests.

Orthoses (exoskeletons and fracture fixation devices) enhance users’ ability to function and improve their quality of life by supporting alignment correction, restoring mobility, providing protection, immobilisation and stabilisation. Ideally, these devices should be personalised to each patient to improve comfort and performance. Production costs have been one of the main constraints for the production of personalised orthoses. However, customisation and personalisation of orthoses are now possible through the use of additive manufacturing. This paper presents the current state of the art of additive manufacturing for the fabrication of orthoses, providing several examples, and discusses key research challenges to be addressed to further develop this field.