Local and global influencing factors on support-free manufacturability in powder bed fusion of metals using a laser beam

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Investigation reveals a process window for overhang angles in PBF-LB/M, implying improved fabrication with thermal consideration.

Successful fabrication of overhang angles as low as 25° demonstrated with increased downskin laser power beyond the standard.
Optical tomography analysis revealed critical insights into localized heat accumulations affecting process stability.
This observational analysis assessed overhang failures, highlighting the deformation evolution prior to failure events.
These findings suggest that traditional design approaches must adapt to include thermal dynamics for robust PBF-LB/M processes.

Beuerlein et al. (2025) studied this question.

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