Development of laser powder bed fusion technology using consolidated powder formed by infrared heating as support structure

In conventional laser powder bed fusion (PBF-LB/M) processes, three-dimensional (3D) printed parts are typically secured to a baseplate using support structures to prevent their movement and thermal deformation. However, removing these supports can often be challenging or even impossible, which results in decreased printing efficiency and limited design freedom. In this study, a novel approach was developed for printing metal parts without the use of conventional support by employing focused infrared (IR) heating in conjunction with conventional PBF-LB/M process. The effectiveness of the proposed approach was validated by successfully printing 3D structures (an unprecedented 18-mm-long 0-degree overhang beam) using Ti-6Al-4 V powder without using support structures. An IR-heated powder with loose consolidation functions as both a reinforcing structure and a heat sink, providing not only structural support to the part but also withstanding the internal thermal stresses and external impacts attributed to the moving blade. Further, the loosely fused powder can be easily removed from the printed part and reused, thereby saving material. Thus, this proposed approach promises to be a significant step towards the additive manufacturing of intricate metal parts without requiring conventional support structures.