Electropolishing represents an effective route to improve the surface condition of metallic parts produced by Laser Powder Bed Fusion (LPBF). We present a study on AlSi7Mg specimens whose geometry is derived from a mesoscopic “feature-based” description grounded in a space–time mereotopology, as proposed by Douin et al. (2023), in order to isolate the influence of primitives (separation, geometry change, displacement, area variation). The parts are electropolished in a sulfuric acid bath using a single set of process parameters (current density, voltage, temperature). The before/after assessment focuses on (i) surface roughness (Ra, Rz, and Sa/Sz), (ii) dimensional attributes (diameters, thicknesses, center distances), and (iii) surface topography/visual quality. Characterization relies on 3D optical and contact profilometry, dimensional metrology, and surface imaging, with a section-by-section analysis to correlate the measured variations with the mesoscopic configuration derived from Douin et al.’s method. The study aims to quantify, under constant electropolishing parameters, the trade-offs between surface finish and geometric fidelity for AlSi7Mg, and to document the impact of the spatio-temporal primitive field on material removal rate and polishing uniformity. The expected contributions are: (1) a reproducible before/after comparison protocol for LPBF geometries described at the meso-scale, (2) a mapping of dimensional deviations and roughness reduction according to the primitives, and (3) design and metrology guidelines for LPBF aluminum parts subjected to sulfuric electropolishing.

Keywords: Electropolishing, LPBF (Laser Powder Bed Fusion), AlSi7Mg, Sulfuric acid, Surface roughness / surface quality, Feature-based geometry