Advanced Support Structures in Metal Additive Manufacturing: A Comparative Analysis of Porous Media for Enhanced Part Quality and Removal Efficiency

Abstract

In laser powder bed fusion additive manufacturing support, structures are crucial for constructing overhang features and maintaining dimensional accuracy. However, traditional support structures exhibit inherent drawbacks, including compromised surface quality, prolonged postprocessing times, and other challenging requirements. This study investigates innovative approaches to address these issues by analyzing two types of specimens—cuboid and lap shear. The cuboid samples explore the manipulation of process parameters to adjust energy densities, transitioning from powder to porous support structures, with porosity measurement assessment. Subsequently, a shear test specimen objectively evaluates porous support parameters alongside traditional block‐type support, analyzing their impact on removal force, distortion, and surface quality. Results reveal that optimized porous support structures surpass traditional counterparts, showcasing superior surface quality, reduced removal forces, and minimized part distortion. Specifically, the shear test demonstrates a 94.25% reduction in removal forces and a 33.67% decrease in upper part distortion. Moreover, the maximum surface roughness (Rz) improves by 22.8% with the implementation of porous supports. By introducing a methodology for comparative analyses of measurable performance indicators, this research enhances understanding of support structure dynamics in additive manufacturing, facilitating advancements in efficiency and quality within the field.