Rapid fabrication of metallic mechanism joints by selective laser melting

When fabricating metallic mechanism joints by selective laser melting (SLM), the clearance of the joint and the fabrication direction are two important factors, which are studied in this paper. In order to reduce joint clearance and facilitate the removal of support material, two improved joint designs are proposed: one with a drum-shaped hub design, and one with a drum-shaped pin design. As well as joint clearance, part strength is also very important. Sample tensile test parts were fabricated by SLM and tested for yield strength and elongation: these mechanical properties were comparable to those of equivalent parts produced by casting. For experimental verification, a number of metallic joints are fabricated. Since non-assembled metallic mechanisms produced by SLM have strength that can stand large loads, they have the potential to be used directly as mechanical power transmission systems in some practical applications.