Analysis of self-supporting structures in additive laser powder bed fusion technology LPBF

Abstract

Through additive technologies, a multitude of functional parts can be manufactured thanks to the versatility of the manufacturing process. Some of these advantages include the ability to create rapid metal prototypes, the option to fabricate with various materials, flexibility in production, and cost savings. This technology is constantly evolving and improving. The present work presents a study to evaluate the effects of printing parameters on surface roughness and dimensional accuracy of lower surfaces without the need for support structures. The material used in the study is 316L stainless steel, an austenitic stainless steel commonly employed in additive manufacturing. The analysis focuses on evaluating the relative fusion energy density by modifying four of the most influential parameters in the LPBF process: laser power, scanning speed, hatch spacing, and frequency. Using the design of experiments (DoE) method, the process parameters will be determined, and the significance and contribution of the individual process parameters to each response will be analyzed. This study provides a solution to a problem related to the manufacturing of self-supporting structures in critical angle situations on the Alba 300 printer by SamyLabs. The optimal reduction in energy density is 40% for a critical angle of 36º and a layer thickness of 50µm.