Experimental and Computational Study on the Influence of Recoater Geometry, Recoating Speed, and Layer Thickness on Recoater Collision

Laser Powder Bed Fusion (LPBF) was used as a cost-effective, sustainable alternative to conventional subtractive methods. In this study, a finite element model was developed to investigate the effects of recoater geometry, recoating speed, and layer thickness on the mechanical performance of printed parts. The model incorporated a temperature-dependent elastic–plastic material law. Two blade types were were tested experimentally: a compliant rubber blade and a rigid ceramic blade. The experimental findings were used in the simulation as a print-failure criterion. The results validated the fixture-based measurements, demonstrating that the compliant blade did not impose significant mechanical stress on the printed part, even when the gap beneath the blade was fully closed. It was found that increasing the cooling time before depositing a new layer reduced the likelihood of build failure due to collisions between the sample and the recoater blade.