Part separation and subsequent adhesive bonding of additively manufactured (AM) subcomponents is a promising strategy to overcome manufacturing constraints and improve cost efficiency of AM processes. This study presents a three-dimensional scarf joint geometry, designed to maximize bond strength at a minimum use of substrate volume. Based on geometrical measurements, measures for improved accuracy of fit between PBF-LB/M substrates made of AlSi10Mg and Ti6Al4V were derived. Static tensile tests confirmed an almost twofold increase in bonding performance compared to conventional scarf joints.
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Ascher et al. (2026) studied this question.
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