Enabling Cost-Based Support Structure Optimization in Laser Powder Bed Fusion of Metals

Abstract Support structures are essential to laser powder bed fusion (PBF-LB/M). They sustain overhangs, prevent distortion, and dissipate process-induced heat. Their removal after manufacturing is required, though, increasing the overall costs. Therefore, optimization important increase economic efficiency of PBF-LB/M. To enable focused on support structures’ costs, a cost model developed. The whole production process, including design, manufacturing, post-processing part, considered by deriving formulas for individual applied previously developed benchmark procedure. Additionally, case study investigating different layout strategies conducted.