Support optimization for overhanging parts in direct metal laser sintering

Abstract

The present work focuses mainly on the utilization of different support profiles for overhang structures in EOS M290 Direct Metal Laser Sintering (DMLS) machine. Maraging steel (MS1) parts with large overhangs were produced using various support parameters to reveal the effects of support profile on dimensional stability of overhang structures and surface quality of the downward facing surfaces. Overhangs supported by weak support profiles require less post processing due to easy support removal and low surface roughness values at the cost of dimensional stability. On the other hand, parts with stronger support profiles are less prone to thermal warping and provided better dimensional stability at the cost of surface quality. The hardness shows no remarkable variation along the overhang surface in the same structure as well as between different parts. The study reveals that the designer should choose different support assemblies depending upon the overhang surface size and location.