Digitalization of design for support structures in laser powder bed fusion of metals

Additive manufacturing is considered a key technology for digital production. However, several barriers towards the broad industrial application exist, e.g. the associated cost and the required experience regarding the manufacturing process. To eradicate these barriers, the complete digitalization of the value creation process is needed. In this thesis, a digital, automated support structuredesign procedure is developed. Topology optimization is used for design rule determination, and the space colonization algorithm is adapted for the automated design. The validity of the procedure is proven experimentally, revealing sufficient mechanical performance alongside cost reduction at medium to large production scales.

Provides a concise review of support structure optimization in laser powder bed fusion Includes thermo-mechanical material model of Ti-6Al-4V alloy Contains cost model for calculation of support-induced costs

Autorentext
Katharina Bartsch studied mechanical engineering with a focus on product development, materials and production at the Technical University of Hamburg. Here, she received her doctorate in 2022 under Prof. Dr.-Ing. Claus Emmelmann (Institute for Laser and System Technologies - iLAS). During her time as a doctoral candidate, she worked as a research associate as well as chief engineer (since 2020) at the iLAS and as a team leader and research associate (since 2019) at the LZN Laser Zentrum Nord GmbH, later Fraunhofer Research Institution for Additive Production Technologies IAPT.

Inhalt

Digital production by additive manufacturing.- Research Hypothesis and Methodology.- Material Model of Ti-6Al-4V Alloy in Laser Powder Bed Fusion.- Support Structure Topology Optimization.- Support Structure Design.- Support Structure Performance Benchmark.- Demonstration of algorithmic support structures.