First-time-right printing of compliant mechanisms manufactured with standard Laser Powder Bed Fusion process parameters: an investigation of the impact of manufacturing defects on the stiffness of thin structures.

First-time-right printing of compliant mechanisms manufactured with standard Laser Powder Bed Fusion process parameters: an investigation of the impact of manufacturing defects on the stiffness of thin structures. | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article First-time-right printing of compliant mechanisms manufactured with standard Laser Powder Bed Fusion process parameters: an investigation of the impact of manufacturing defects on the stiffness of thin structures. Guilain Lang, Julien Rouvinet, Lionel Kiener, Mirko Meboldt This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7805034/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 31 Mar, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract Compliant mechanisms achieve motion through elastic deformation of slender blades, offering high precision and eliminating issues such as friction, backlash, and lubrication needs, making them particularly attractive for space scientific instrumentation applications. While Additive Manufacturing (AM), particularly Laser Powder Bed Fusion (LPBF), enables the fabrication of such monolithic structures, their performance is highly sensitive to manufacturing defects. As such, their manufacturing traditionally requires a resource-intensive optimization of the LPBF process. In this study, we model the impact of surface roughness, surface offset, and internal porosity on the as-built stiffness of Ti-6Al-4V cantilevers. Based on scanning electron microscopy of five representative samples, we developed a high-fidelity predictive model that estimates stiffness with a mean error of 3.31% across 43 samples (standard deviation: 4.99% Building on this model, we introduce a preventive correction strategy that adjusts nominal geometry to achieve target stiffness values. This approach was validated on 15 corrected samples, achieving a mean error of just 1.32% . Finally, we extended the methodology to more complex systems - a cross-axis flexural pivot and a 2-DOF compliant pointing mechanism - demonstrating similar accuracy under alternative loading conditions These results confirm that our strategy enables first-time-right printing of compliant mechanisms using standard LPBF parameters, making functional AM accessible even without extensive process optimization. Design for AM Compliant Mechanisms Preventive Correction Thin Structure First-time-right printing Full Text Cite Share Download PDF Status: Published Journal Publication published 31 Mar, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Major Revisions Needed 04 Jan, 2026 Reviewers agreed at journal 27 Oct, 2025 Reviewers invited by journal 27 Oct, 2025 Editor assigned by journal 10 Oct, 2025 First submitted to journal 09 Oct, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7805034","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":535750566,"identity":"686af22f-2cd8-427c-a839-80dc4e9914e6","order_by":0,"name":"Guilain 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