Selection of Processing Parameters in Laser Powder Bed Fusion for the Production of Iron Cellular Structures

Metal additive manufacturing (AM) offers promising advancements in producing implants with complex geometry for biomedical applications, where accuracy and near-net-shape production are essential. Metal AM by laser powder bed fusion (PBF-LB) is a promising route to produce biodegradable iron implants made of complex lattice structures. However, processing windows for pure iron remain poorly defined. This work focuses on optimizing PBF-LB parameters for pure iron using a design of experiments (DoE) approach on bulk samples of different geometries to evaluate different parameters. Hatch laser power, scanning speed, hatch distance and point distance were varied and their effect on porosity, surface roughness and dimensional accuracy was evaluated. This was followed by the fabrication of rhombitruncated cuboctahedron (RTCO) lattice structures with the best parameters previously defined for the bulk samples. The best parameter set (hatch laser power 180 W, scanning speed 600 mm/s, hatch distance 110 µm and point distance 12 µm, corresponding to a volumetric energy density of 90.9 J/mm3) produced bulk samples with a porosity as low as 0.07% (99.93% density) measured in polished sections. Using these parameters, RTCO lattices with designed relative densities of 10.28%, 35.29% and 65.16% were successfully manufactured with small geometric deviations and good control of strut thickness and relative density. The results of this study define a robust PBF-LB processing window for pure iron and demonstrate the feasibility of producing geometrically controlled, biodegradable iron lattice structures suitable for future load-bearing biomedical applications.