Rapid Material Multiparameter Optimization for Small-scale Series Productions in PBF-LB/M

Materials development is an increasingly researched area within additive manufacturing. Companies with special product requirements are looking toward combining the unique properties of special alloy classes with the geometrical benefits of additive manufacturing (AM). In this contribution a method for rapid multiparameter optimization for Laser Powder Bed Fusion in Metals (PBF-LB/M) is described. Parameter sets for multiple quality features such as surface roughness, down face integrity, mechanical performance, and bulk density are optimized simultaneously using compact Design of Experiment approaches. The method is demonstrated on a case component with requirements on weldability, corrosion resistance, and mechanical resistance which led to the need for rapid powder manufacturing and printing parameter optimization in stainless steel 310S-an alloy not typically available on the PBF-LB market. The method resulted in rapidly developed processing parameters for 310S producing high-quality parts befitting the requirements of the case component. The result showcases the potential for short lead times and product development using simple Design of Experiment approaches for materials and parameter development within PBF-LB/M.