Novel approach for fabricating horizontal overhanging structures in selective laser melting

The fabrication of overhanging structure is difficult in Selective laser melting. Currently, temporary supports must be installed when fabricating horizontal overhanging structures, but this method inevitably results in additional waste. This paper presents an original study for the fabrication of horizontal overhanging structure. By using a defocused laser, a new structure layer was successfully printed directly on the powder bed, which was used as the initial layer of a horizontal overhanging structure to replace the traditional supports. As a feasibility check, a closed box with a large horizontal top was printed. The experimental results show that the new approach can significantly reduce the additional waste caused by conventional supports.

Automated summary

Fabricating overhanging structures in Selective laser melting is challenging. Temporary supports are currently required, but they generate additional waste. This study proposes a new method by using a defocused laser to print a new structure layer directly on the powder bed, eliminating the need for traditional supports. Experimental results demonstrate that this approach can greatly reduce waste caused by conventional supports.