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Metal additive manufacturing has shown great potential in aerospace, medical, and automobile industries; however, distortion of metal part has been an obstacle in widespread application of metal additive manufacturing. The mechanism of thin-walled structure distortion remains unrevealed. In this study, the origin of distortion of thin-walled structure was discussed, based on the previously proposed assumption of constraining force-induced distortion. The relation between the microstructure and macro-distortion has been linked via the constraining force. The influence of scan directions and structure sizes on the distortion was also studied, and the approaches to decrease the thin-walled structure were discussed. Use of the alternant scan strategy has been validated as an effective approach if the structure sizes cannot be adjusted.

Distortion of Thin-Walled Structure Fabricated by Selective Laser Melting Based on Assumption of Constraining Force-Induced Distortion