A comprehensive study of LPBF parameter influence in 316L stainless steel mechanical properties, macrostructure, and printability

Additive manufacturing, particularly using Laser Powder Bed Fusion (LPBF) technologies with 316L stainless steel, has proven highly promising in biomedical engineering due to the material’s exceptional mechanical properties and biocompatibility. This study, which is a foundational step towards developing porous bone implants, focuses on assessing the influence of a broad range of parameters - spot size, scanning speed, laser power, and energy density - on the mechanical performance and structural integrity of 316L stainless steel parts across three distinct specimen geometries: fully dense parallelepipedic, fully dense cubic, and cellular (lattice) specimens. By analysing 17 different parameter sets and producing over 150 specimens, a thorough series of experimental tests were conducted, including flexural tests, compression tests, hardness tests, macroscopic evaluation of the surface of fully dense specimens, and macroscopic evaluation of the lattice structures.e in powder accumulation within the pores of cellular structures, with higher energy densities (100 J/mm 3 ) leading to a significantly greater retention compared to lower energy densities (66 J/mm 3 ). This underexplored phenomenon has significant implications for the selection of parameters in the fabrication of bone implants. Further research is needed to refine LPBF printing parameters and enhance the quality of porous bone implants.