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Updated: Jul 10, 2025

Indirect Fabrication of Lattice Metals with Thin Sections Using Centrifugal Casting

Indirect Fabrication of Lattice Metals with Thin Sections Using Centrifugal Casting

Published on: May 14, 2016

Support Structures Optimisation for High-Quality Metal Additive Manufacturing with Laser Powder Bed Fusion: A

Antonios Dimopoulos¹, Mohamad Salimi², Tat-Hean Gan^1,2,3

¹Department of Mechanical and Aerospace Engineering, Brunel University London, Uxbridge UB8 3PH, UK.

Materials (Basel, Switzerland)

|November 25, 2023

Summary

Optimizing support structures in metal additive manufacturing (AM) using Laser Powder Bed Fusion (LPBF) reduces residual stress and improves part quality. Block supports offer superior thermal performance, minimizing warping and enhancing component integrity.

Keywords:

additive manufacturing laser powder bed fusion metal support structures multi-objective optimisation numerical modelling thermo-mechanical analysis titanium alloy

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Last Updated: Jul 10, 2025

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Published on: March 13, 2018

Area of Science:

Materials Science
Mechanical Engineering
Manufacturing Technology

Background:

Metal Additive Manufacturing (AM) enables complex, lightweight components.
Laser Powder Bed Fusion (LPBF) is a key AM technique but suffers from high residual stress, leading to part defects and failures.

Purpose of the Study:

To evaluate the thermal behavior of various support structures in LPBF.
To optimize support designs for reduced support volume and residual stress.
To ensure high-quality prints in metal AM processes.

Main Methods:

Experimental printing of L-shaped specimens using block-type supports on an LPBF machine.
Numerical simulations to validate experimental findings and analyze line, contour, and cone supports.
Design of Experiments (DOE) and multi-objective optimization for support structure assessment.

Main Results:

Block supports demonstrated excellent thermal behavior during the LPBF process.
High-density supports showed better temperature distribution compared to low-density supports.
Cone-type supports were found to be more prone to warping issues.

Conclusions:

Support structure design significantly impacts thermal behavior and residual stress in LPBF.
Block and high-density supports are effective in mitigating defects and improving print quality.
Findings offer guidance for advancing metal AM applications in aerospace, medical, and automotive sectors.