Investigation of the effect of functional porous support structures on part quality and removal properties in laser powder bed fusion

This study explores the design and evaluation of support structures in laser powder bed fusion additive manufacturing, with a particular focus on developing functionally graded support structure designs to overcome the limitations of traditional supports. Although traditional support structures are assumed to offer mechanical stability, they typically demand significant removal forces. High removal forces can jeopardize delicate features, particularly in components with thin structures, like those used in lightweight aerospace applications and heat exchangers. Proposed novel approach by integrating gradual transitions among porous support structures, which not only enhance the stability but also penetrate the part to improve surface quality while reducing the required effort for removal. The findings reveal that functionally graded support structure designs significantly outperform traditional supports. The functionally graded support structure design achieved a remarkable 95.91 % reduction in removal force, minimizing displacement at fracture by 88.94 %, and 29.0 % lower part deviation compared to conventional designs. This innovative approach minimizes post-processing requirements, allowing for the manufacture of thinner components that fulfil the strict performance and weight standards of aerospace and other high-performance sectors.