Investigation of novel support structure in power bed fusion

• Main Author: Ang, Elias Yu Chen
• Other Authors: Yeong Wai Yee
• Format: Final Year Project
• Language: English
• Published: Nanyang Technological University 2024
• Subjects: Engineering; 3D printing
• Online Access: https://hdl.handle.net/10356/176861
• Institution: Nanyang Technological University

This study explores the optimization of support structures in metal powder bed fusion (PBF) 3D printing, focusing on the potential of loose and solidified powder supports. Through a series of experiments, we investigated the effects of various parameters such as laser power, scan speed, hatch spacing, and layer thickness on the quality and feasibility of these innovative support structures. Our research highlights the importance of maintaining a specific temperature range (200 to 300°C) for the successful solidification of powder, and the critical role of time in achieving optimal results. Despite time and resource limitations, the experiments provided valuable insights into the conditions needed for powder solidification, identifying a key energy exposure density of 2520 kJ/m² as a benchmark for future studies. The findings suggest promising directions for enhancing the efficiency and viability of support structures in commercial PBF applications, including the incorporation of design elements like fins to improve heat dissipation. This study lays the groundwork for future research aimed at advancing the capabilities and applications of metal PBF 3D printing.