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Simulation-Based Support Generation for Laser Powder Bed Fusion Processes.

Eugen Boos1, Steffen Ihlenfeldt1,2, Nikolaus Milaev2

  • 1TU Dresden, Dresden, Germany.

3D Printing and Additive Manufacturing
|May 1, 2023
PubMed
Summary

This study introduces a simulation-based method for designing additive manufacturing support structures. It minimizes residual stresses and material usage, improving component quality and reducing costs.

Keywords:
finite element methodgenerative designlaser powder bed fusionoptimizationsupport structurestailored lattice structures

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Area of Science:

  • Additive Manufacturing
  • Materials Science
  • Mechanical Engineering

Background:

  • Laser powder bed fusion enables advanced designs but faces challenges with residual stresses and component warpage.
  • Current support structures primarily address geometric needs, not process-induced stresses.
  • High-performance industries require stringent quality standards unmet by existing methods.

Purpose of the Study:

  • To develop a simulation-based approach for generating topology-optimized support structures that minimize residual stresses.
  • To integrate stress analysis into the design of support structures for improved additive manufacturing quality.
  • To enhance cost-efficiency through optimized material usage and easy support removal.

Main Methods:

  • Utilized thermomechanical finite element process simulations to determine stress distributions.
  • Employed topology optimization for allocating stackable unit cells based on stress data.
  • Investigated and integrated novel connection structures for reliable yet removable support interfaces.
  • Validated the approach on a demonstrator part printed with AlSi10Mg.

Main Results:

  • Developed a tailored lattice support structure that effectively minimizes residual stresses.
  • Achieved high component quality by mitigating warpage and deformations.
  • Demonstrated cost-efficiency via reduced material consumption and simplified support removal.
  • Validated the numerical efficiency and robustness of the proposed simulation-based method.

Conclusions:

  • The simulation-based approach offers a significant advancement over geometric-only methods for support structure generation.
  • This method enables the production of high-quality components in demanding industries like aerospace and automotive.
  • Optimized support structures contribute to the broader industrial adoption of additive manufacturing technologies.