OLA

Case Study: Multi-Feature Functional Test Cube

316L Stainless Steel | SLM | Compact Test Coupon with Internal Channels and Marked Surfaces

Metal 3D Printing Application

1. Background

A quality engineering team needed a compact, repeatable test coupon to validate SLM process capability across multiple geometries at once. The coupon had to include internal curved channels (for flow and CT-scan validation), a range of hole sizes (for resolution and roundness checks), raised 3D-marked identification labels (for traceability), and external mounting features (for in-service fixture testing). A traditional machined test block could not deliver the internal channels and the 3D-marked text in the same part.

2. The Challenge

Design requirements included:

· Internal curved channels with 90° turn, no support marks on wetted surface

· Six different hole diameters from 1.5 mm to 10 mm on a single face

· Raised 3D-marked labels ('Test Note 2/3/4/5') on the front face for traceability

· External curved pipe features on the top for flow-loop integration

· Compact envelope: ~70 mm cube, with 5 mm minimum wall on every internal feature

3. The Solution

The test cube was designed as a single part with internal curved channels, six different hole sizes on the side faces, and raised 3D-marked labels on the front face, then manufactured by Selective Laser Melting (SLM) in 316L stainless steel in a single build. The internal channels were oriented to be self-supporting during printing, eliminating the need for internal support structures. The 3D-marked text was printed as raised characters in the same build, giving every coupon a permanent, tamper-proof identifier. After printing, the cube was bead-blasted for a uniform finish and the hole faces were left as-printed for roundness measurement.

 

Figure 1: SLM-printed 316L test cube — front view with raised 3D-marked 'Test Note 2/3/4/5' labels, side hole pattern, and top curved pipe features

 

Figure 2: Same test cube from the rear angle — shows side-face hole diameters from 1.5 mm to 10 mm and the internal chamber access

 

Figure 3: Three-quarter view — compact 70 mm envelope with all six validation features in a single part

4. The Result

· Single-build coupon — internal channels + 6 hole sizes + 3D-marked text in one part

· Permanent 3D labels — raised characters, cannot be removed or sanded off

· Internal curved channel — self-supporting geometry, no support marks on wetted surface

· Multi-feature validation — flow test + CT scan + roundness check on one coupon

· Lead time: 2 weeks — from CAD to finished, bead-blasted coupon

· Reusable for QA — calibration and process-capability validation standard

“This one coupon replaced three separate validation blocks. Our process-capability dashboard is now built around a single, repeatable part.”

 

Material: 316L Stainless Steel  |  Process: SLM / Metal 3D Printing  |  Application: Multi-Feature Test Coupon