Utilizing lattice support structures in electron beam additive manufacturing

Using the support structures in producing overhang structures via Electron Beam melting (EBM) is essential, but it results in higher material consumption, and higher post-processing time and costs. In this study, lattice structures with a relatively minimal volume fraction and post-processing time are utilized to support parts produced via EBM. Two types of lattice structures, Diamond and Dode-thin, have been considered in this study. The impact of design and process parameters support of metal lattice support on support removal time and overhang deformation is also evaluated. The findings demonstrate that lattice structures function effectively as support for EBM overhangs with a reduction percentage of support volume of 46.73% for the Diamond structure and 66.23% for the Dode structure and a reduction in removal time of 45.91% for the Diamond structure and 63.2% for the Dode structure compared with block support structures with a slight increase in part deformation. The findings also indicate that the performance of lattice support structures is effected by it’s design and process parameters; nevertheless, these effect was not significant.