Influence of the layer thickness on the dimensional accuracy and mechanical properties of lattice structures during PBF-LB of AlSi10Mg

Laser powder bed fusion has emerged as a key additive manufacturing technology for manufacturing complex high-performance structures. However, a downside of the technology is the productivity of large-scale manufacturing in comparison to conventional manufacturing technologies. One of the critical parameters influencing the quality, productivity, and performance of PBF-LB-manufactured components is the layer thickness. A higher layer thickness accelerates manufacturing and reduces costs due to lower process times. On the downside, higher layer thicknesses may introduce dimensional inaccuracies, porosity due to incomplete fusion and increased surface roughness which ultimately compromises the component performance. While there are several studies about the influence of the layer thickness on bulk material, cellular materials like strut-based lattice structures are less investigated. By analyzing the strut morphology, dimensional accuracy, surface roughness and mechanical performance in relation with the productivity across different layer thicknesses, this work provides insights into process optimization for lattice structures using AlSi10Mg. Understanding the correlation between layer thickness, lattice quality, and manufacturing efficiency is essential for enhancing structural reliability, functional performance, and cost-effectiveness in PBF-LB applications.