Laser powder bed fusion process parameters for the fabrication of unsupported overhang structures of metamaterial lattices

Wessel W. Wits; Camill de Vos; Maria Montero-Sistiaga; Marc de Smit

doi:10.1016/j.cirp.2025.03.003

Laser powder bed fusion process parameters for the fabrication of unsupported overhang structures of metamaterial lattices

Wessel W. Wits^*, Camill de Vos, Maria Montero-Sistiaga, Marc de Smit

^*Corresponding author for this work

Multiscale Modeling and Simulation

Research output: Contribution to journal › Article › Academic › peer-review

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Abstract

Laser powder bed fusion of unsupported overhang structures, required for metamaterial lattices, are difficult to manufacture. In this study, process parameters are experimentally determined to successfully fabricate auxetic re-entrant metamaterial structures. Due to the support-less printing, higher linear energy densities compared to contour and hatch scanning are required to build continuously solidified overhang structures. Simulation results show that the melt pool width and in particular the length is enlarged, promoting loose powder attachment by denudation and balling. Auxetic re-entrant metamaterials are successfully fabricated. Impact tests show good mechanical performance and better energy absorption compared to previous studies.

Original language	English
Journal	CIRP Annals
DOIs	https://doi.org/10.1016/j.cirp.2025.03.003
Publication status	E-pub ahead of print/First online - 4 Apr 2025

Keywords

UT-Hybrid-D
Metamaterials
Powder bed fusion (PBF)
Additive manufacturing (AM)

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1016/j.cirp.2025.03.003Licence: CC BY

1-s2.0-S0007850625000058-mainFinal published version, 2.14 MBLicence: CC BY

Cite this

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title = "Laser powder bed fusion process parameters for the fabrication of unsupported overhang structures of metamaterial lattices",

abstract = "Laser powder bed fusion of unsupported overhang structures, required for metamaterial lattices, are difficult to manufacture. In this study, process parameters are experimentally determined to successfully fabricate auxetic re-entrant metamaterial structures. Due to the support-less printing, higher linear energy densities compared to contour and hatch scanning are required to build continuously solidified overhang structures. Simulation results show that the melt pool width and in particular the length is enlarged, promoting loose powder attachment by denudation and balling. Auxetic re-entrant metamaterials are successfully fabricated. Impact tests show good mechanical performance and better energy absorption compared to previous studies.",

keywords = "UT-Hybrid-D, Metamaterials, Powder bed fusion (PBF), Additive manufacturing (AM)",

author = "Wits, {Wessel W.} and {de Vos}, Camill and Maria Montero-Sistiaga and {de Smit}, Marc",

note = "Publisher Copyright: {\textcopyright} 2025 The Author(s)",

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doi = "10.1016/j.cirp.2025.03.003",

language = "English",

journal = "CIRP Annals",

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T1 - Laser powder bed fusion process parameters for the fabrication of unsupported overhang structures of metamaterial lattices

AU - Wits, Wessel W.

AU - de Vos, Camill

AU - Montero-Sistiaga, Maria

AU - de Smit, Marc

PY - 2025/4/4

Y1 - 2025/4/4

N2 - Laser powder bed fusion of unsupported overhang structures, required for metamaterial lattices, are difficult to manufacture. In this study, process parameters are experimentally determined to successfully fabricate auxetic re-entrant metamaterial structures. Due to the support-less printing, higher linear energy densities compared to contour and hatch scanning are required to build continuously solidified overhang structures. Simulation results show that the melt pool width and in particular the length is enlarged, promoting loose powder attachment by denudation and balling. Auxetic re-entrant metamaterials are successfully fabricated. Impact tests show good mechanical performance and better energy absorption compared to previous studies.

AB - Laser powder bed fusion of unsupported overhang structures, required for metamaterial lattices, are difficult to manufacture. In this study, process parameters are experimentally determined to successfully fabricate auxetic re-entrant metamaterial structures. Due to the support-less printing, higher linear energy densities compared to contour and hatch scanning are required to build continuously solidified overhang structures. Simulation results show that the melt pool width and in particular the length is enlarged, promoting loose powder attachment by denudation and balling. Auxetic re-entrant metamaterials are successfully fabricated. Impact tests show good mechanical performance and better energy absorption compared to previous studies.

KW - UT-Hybrid-D

KW - Metamaterials

KW - Powder bed fusion (PBF)

KW - Additive manufacturing (AM)

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DO - 10.1016/j.cirp.2025.03.003

M3 - Article

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SN - 0007-8506

JO - CIRP Annals

JF - CIRP Annals

ER -

Laser powder bed fusion process parameters for the fabrication of unsupported overhang structures of metamaterial lattices

Abstract

Keywords

UN SDGs

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