On resource efficient and individualized tree support structures for PBF-LB/M by process simulation

Laser powder bed fusion of metals (PBF-LB/M) is a widely used additive manufacturing process known for its ability to create complex geometries with high precision. However, the necessity of support structures in PBF-LB/M leads to significant material and energy consumption, impacting overall efficiency. This work investigates a novel approach combining numerical process simulation with a user-friendly software tool to design resource-efficient tree support structures. A demonstrator part, manufactured from Ti6Al4V titanium ally, is used to validate the effectiveness of these generative support designs. The accuracy of the process simulation is assessed by comparing numerical results with geometrical deviations, obtained by 3D scanning the additively manufactured demonstrator parts. Additionally, the newly designed support structures are compared against widespread block supports, focusing on material consumption and geometrical precision. The demonstrator with tree supports shows 34.48 % less mean deviation than the one with block supports while being slightly lighter. These results demonstrate that the presented approach allows for the creation of individualized and efficient tree support structures, leading to faster print preparations, less misprints and therefore reduced manufacturing costs. Moreover, new manufacturing limits for thin rods in PBF-LB/M are identified by the successful fabrication of 50 mm long rods with minimum diameters of 0.3 mm and inclination angles to the built plate greater than 20 °, as well as vertical rods up to 300 mm in length. This increases the design freedom for components and support structures in PBF-LB/M processes drastically. Overall, the integration of advanced support design techniques shows promise for enhancing the sustainability and cost-effectiveness of PBF-LB/M.