Scanpath Centric Design for miniaturizing PBF-LB/M Prints

Abstract

Powder bed fusion with laser beam of metals (PBF-LB/M) allows for solid models ('solids') and non-solid models ('surfaces') to be transferred into the physical domain, e.g. to be materialized. Typically, solids are used to represent parts, and both solids and non-solids are used to act as support structures. The widely implemented concept, supplemented with conversions known as 'slicing' and 'hatching', is sufficient in most cases. However, it leaves only little room for the engineer to control the exact location of the scanpath in each of the layers. Furthermore, it does not provide full feedback about the scanpath to the engineer in the product design process proceeding the materialization. The study attempts to find a way to overcome such lack of control, particularly in case of the tiniest spatial elements, and aims to increase the deployability of powder bed fusion with laser beam of metals in its most popular form, including improved detailing. A new methodology was developed to generate curves to act as scanpath, fully accessible to the engineer. Examples of relevant applications for this new strategy include (small, monolithic integrated) leaf springs and tubes which by applying this approach may become denser, less rough and more accurate, and consequently less porous and more durable.