Abstract

This study examines the fabrication of toothed wheels from 316L stainless steel using powder bed fusion (PBF), evaluating
surface roughness, dimensional fidelity, and mechanical performance in the as-built condition. Results reveal near-net shape
(NNS) accuracy, within±0.05 mm of the intended geometry, and a tensile strength of 720 MPa, exceeding many traditional
manufacturing processes. The rapid cooling characteristic of PBF induces a refined, nearly pore-free microstructure, driv�ing Vickers hardness values up to 244.5 HV. Although no post-processing was used, average surface roughness remained
at a modest 27.5 µm (ISO 1302 N11), emphasizing PBF’s ability to fabricate complex features without compromising the
overall finish. Thermodynamic simulations illustrate that secondary carbide formation and internal stresses contribute to
the alloy’s improved strength, though the emergence of the sigma phase could locally reduce corrosion resistance. These
findings emphasize the potential of PBF to deliver both dimensional precision and mechanical robustness in components
subject to high-load, high-precision applications. Looking ahead, expanding the range of materials and refining process
parameters, including laser power and scanning speed, offer promising directions for further performance gains and broader
industrial adoption.
Keywords Additive manufacturing · 3D printing · Powder bed fusion (PBF) · 316L stainless steel