An Accessibility Assessment Algorithm for Support Structure Removal in Parts Produced by Powder Bed Fusion of Metal Using a Laser Beam

In the additive manufacturing process of Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M), the removal of support structures represents a costly step, predominantly carried out manually in current industrial practices. Particularly challenging are areas of the parts where tools for support removal struggle to access. Therefore, in the data preparation of parts manufactured via PBF-LB/M, attempts are often made to orient the parts within the build chamber in such a way that no supports are needed in the difficult-to-access areas. However, identifying these areas is error-prone and typically relies on manual evaluation by engineers. To reduce susceptibility to errors, this paper introduces an algorithm called the Accessibility Assessment Algorithm (AAA), which automatically evaluates the accessibility of parts. The algorithm is implemented and tested on ten parts. Five experts experienced in removing support structures from PBF-LB/M-printed parts are interviewed and asked to evaluate the same parts for inaccessible areas, and then to assess the calculation results of the AAA. Subsequently, the results regarding inaccessible areas are compared between the algorithm's assessment and the experts’ evaluations. The results show a 70.5% agreement, indicating its effectiveness in assessing the accessibility of parts.