Optimization of support structures for the laser additive manufacturing of TiAl6V4 parts

Abstract

For the successful production of parts with Laser Beam Melting technology support structures are essential. Their main functions are to support overhanging structures, dissipate the heat generated during the process, and minimizing geometrical distortions caused by internal stresses. Although support structures play an important role in the SLM process, they must be removed during the post-processing stage as they do not constitute part of the final geometry. An optimization of the support structures would lead to a reduction in the material consumption during the production process and a significant reduction of the time and effort required during post-processing. This paper investigates the properties of different types of support structures, in particular the strength of the connection between support structures and the part. The strength of the connections between the support structure and the part was investigated through experimentations. Finally, this paper offers a series of guidelines aimed at helping process engineers to select the right design of the support structure when preparing a print job. The determined strengths and geometrical recommendations were used for automated support simulations.