Multi-Response Optimization of Ti6Al4V Support Structures for Laser Powder Bed Fusion Systems

Laser Powder Bed Fusion (LPBF) is one of the most commonly used and rapidly developing metal Additive Manufacturing (AM) technologies for producing optimized geometries, complex features, and lightweight components, in contrast to traditional manufacturing, which limits those characteristics. However, this technology faces difficulties with regard to the construction of overhang structures and warping deformation caused by thermal stresses. Producing overhangs without support structures results in collapsed parts, while adding unnecessary supports increases the material required and post-processing. The purpose of this study was to evaluate the various support and process parameters for metal LPBF, and propose optimized support structures to minimize Support Volume, Support Removal Effort, and Warping Deformation. The optimization approach was based on the Design of Experiments (DOE) methodology and multi-response optimization, by 3D printing and studying overhang geometries from 0° to 45°. For this purpose, EOS Titanium Ti64 Grade 5 powder was used, a Ti6Al4V alloy commonly employed in LPBF. For 0° overhangs, the optimum solution was characterized by an average Tooth Height, large Tooth Top Length, low X, Y Hatching, and high Laser Speed, while for 22.5° and 45° overhangs, it was characterized by large Tooth Height, low Tooth Top Length, high X, Y Hatching, and high Laser Speed.