2026 Undergraduate Research Showcase

Micro Dimensional Analysis of 3D Printed Stainless Steel

Document Type

Student Presentation

Presentation Date

4-24-2026

Faculty Sponsor

Dr. Todd Otanicar

Abstract

Micro-scale dimensional analysis of 3D printed stainless steel components is performed using micro-computed tomography (micro-CT). The goal is to characterize surface roughness and hydraulic diameter. Additive manufacturing enables complex internal geometries, but introduces surface irregularities and dimensional variability that can significantly influence fluid flow behavior. High-resolution micro-CT scanning provides a non-destructive approach to capture both internal and external geometries of printed samples with high fidelity.

Reconstructed 3D models are used to quantify surface roughness and identify layer-induced features that are difficult to measure using conventional techniques. Hydraulic diameter is evaluated by extracting cross-sectional flow area and wetted perimeter directly from the scan data, allowing for a more accurate representation of actual flow passages compared to nominal design values.

Results indicate measurable deviations between designed and as-built geometries, with surface roughness contributing to reduced effective flow area. These findings emphasize the importance of incorporating as-built micro-scale measurements into performance predictions and demonstrate the usefulness of micro-CT for improving the characterization of additively manufactured components in fluid flow applications.

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