Process and geometrical integrity optimization of electron beam melting for copper

This work systematically analyzes and optimizes the process of electron beam melting for pure copper. It is shown that, reliable manufacturing, preheating temperature should be optimized to avoid porosity as well part deformation. The fully focused prevent shrinkage voids (correlated negative defocusing) material spattering (linked positive defocusing). Smoother surfaces from lower hatch spacing (e.g., 100µm) can improve density reliability, while longer overhangs are reached by a higher spacing. A suitable starting contour strategy also applied mitigate border porosities, reduce side roughness increase geometric precision.