Investigation of process simulation and additive manufacturability of lattice-type support structures

Abstract

Laser powder bed fusion is an additive manufacturing technology that enables manufacturing complex structures with the capability of design freedom. However, owing to the essential nature of the process, it generally requires support structures. Correct selection of support structures allows a part to be manufactured successfully by avoiding inefficient heat dissipation, process-based failures, redundant material usage and long labour intense post-processes. For this purpose, alternative support structures to commercial solutions may be needed for manufacturing of the parts. In this study, different lattice-type support structures with nearly same density are investigated in terms of process simulation, manufacturing and inspection. Process simulation results indicate that the simulated lattice-type support structures exhibit similar trend with the actual ones, although up to 35% discrepancy was seen between displacement values which is a result of modeling thin and complex lattice structures. The results from manufacturing show that the lattice-type support structures present more stability than the perforated block type support structure, although they have the same density. Among the lattice-type support structures, FCC had the minimum deformation in both simulation and manufacturing results. Besides, inspection results show that the manufactured lattice structures have accurate geometrical dimensions which is consistent with its engineering design models.