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Optimization of Parameters of Block-Shaped Support Tooth Structure Using Orthogonal Experimental Design in Laser Powder Bed Fusion.

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Title: Optimization of Parameters of Block-Shaped Support Tooth Structure Using Orthogonal Experimental Design in Laser Powder Bed Fusion.
Authors: Li, Zhongli1 (AUTHOR), Fei, Guosheng1,2 (AUTHOR), Wu, Daijian1,2,3 (AUTHOR), Chen, Xiaoci1 (AUTHOR), Yu, Yingyan2,3 (AUTHOR), Liu, Zuofa2,3 (AUTHOR), Zhang, Jiansheng1,3 (AUTHOR), Zhou, Jie1,2 (AUTHOR)
Source: Materials (1996-1944). Apr2026, Vol. 19 Issue 8, p1480. 17p.
Subjects: Powder bed fusion, Inconel, Structural optimization, Orthogonal arrays, Metrology, Taguchi methods
Abstract: To address the challenges associated with laser powder bed fusion (LPBF) of overhanging structures—namely warping deformation, powder adhesion, and inadequate forming accuracy—this study investigates the optimization of the support–part contact interface using Inconel 625 alloy. The objective is to achieve high-quality part formation with minimal support structures. A Taguchi experimental design was employed to systematically evaluate the effects of key block support parameters—tooth height, tooth top length, tooth base length, and tooth base spacing—on the forming performance of overhanging structures, with forming accuracy and support removability as the optimization targets. The results reveal that tooth top length significantly influences both the forming accuracy of overhanging specimens and the ease of support removal. Specifically, an increase in tooth top length leads to a rapid reduction in specimen deformation, but simultaneously increases the difficulty of support removal. When the tooth top length was set to 0.1 mm, all overhanging specimens failed to form successfully. Tooth base length also plays a critical role in support removability, with removal difficulty initially decreasing and then stabilizing as the tooth base length increases. Based on the trade-off between forming quality and support removability, the optimal parameter combination was identified as: tooth height of 0.4 mm, tooth top length of 0.7 mm, tooth base length of 1.0 mm, and tooth base spacing of 0.3 mm. A validation experiment conducted using this optimized configuration demonstrated good forming accuracy in the support contact area, with a deformation value of −0.208 mm, confirming the effectiveness and reliability of the proposed parameters. This study not only provides a theoretical foundation for the optimal design of block supports in LPBF but also offers experimental data and practical guidance for selecting support parameters in the fabrication of overhanging structures. [ABSTRACT FROM AUTHOR]
Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Label: Title
  Group: Ti
  Data: Optimization of Parameters of Block-Shaped Support Tooth Structure Using Orthogonal Experimental Design in Laser Powder Bed Fusion.
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  Data: <searchLink fieldCode="AR" term="%22Li%2C+Zhongli%22">Li, Zhongli</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Fei%2C+Guosheng%22">Fei, Guosheng</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Wu%2C+Daijian%22">Wu, Daijian</searchLink><relatesTo>1,2,3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Chen%2C+Xiaoci%22">Chen, Xiaoci</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Yu%2C+Yingyan%22">Yu, Yingyan</searchLink><relatesTo>2,3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Liu%2C+Zuofa%22">Liu, Zuofa</searchLink><relatesTo>2,3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Zhang%2C+Jiansheng%22">Zhang, Jiansheng</searchLink><relatesTo>1,3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Zhou%2C+Jie%22">Zhou, Jie</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. Apr2026, Vol. 19 Issue 8, p1480. 17p.
– Name: Subject
  Label: Subjects
  Group: Su
  Data: <searchLink fieldCode="DE" term="%22Powder+bed+fusion%22">Powder bed fusion</searchLink><br /><searchLink fieldCode="DE" term="%22Inconel%22">Inconel</searchLink><br /><searchLink fieldCode="DE" term="%22Structural+optimization%22">Structural optimization</searchLink><br /><searchLink fieldCode="DE" term="%22Orthogonal+arrays%22">Orthogonal arrays</searchLink><br /><searchLink fieldCode="DE" term="%22Metrology%22">Metrology</searchLink><br /><searchLink fieldCode="DE" term="%22Taguchi+methods%22">Taguchi methods</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: To address the challenges associated with laser powder bed fusion (LPBF) of overhanging structures—namely warping deformation, powder adhesion, and inadequate forming accuracy—this study investigates the optimization of the support–part contact interface using Inconel 625 alloy. The objective is to achieve high-quality part formation with minimal support structures. A Taguchi experimental design was employed to systematically evaluate the effects of key block support parameters—tooth height, tooth top length, tooth base length, and tooth base spacing—on the forming performance of overhanging structures, with forming accuracy and support removability as the optimization targets. The results reveal that tooth top length significantly influences both the forming accuracy of overhanging specimens and the ease of support removal. Specifically, an increase in tooth top length leads to a rapid reduction in specimen deformation, but simultaneously increases the difficulty of support removal. When the tooth top length was set to 0.1 mm, all overhanging specimens failed to form successfully. Tooth base length also plays a critical role in support removability, with removal difficulty initially decreasing and then stabilizing as the tooth base length increases. Based on the trade-off between forming quality and support removability, the optimal parameter combination was identified as: tooth height of 0.4 mm, tooth top length of 0.7 mm, tooth base length of 1.0 mm, and tooth base spacing of 0.3 mm. A validation experiment conducted using this optimized configuration demonstrated good forming accuracy in the support contact area, with a deformation value of −0.208 mm, confirming the effectiveness and reliability of the proposed parameters. This study not only provides a theoretical foundation for the optimal design of block supports in LPBF but also offers experimental data and practical guidance for selecting support parameters in the fabrication of overhanging structures. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.3390/ma19081480
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        Text: English
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        PageCount: 17
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      – SubjectFull: Structural optimization
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      – SubjectFull: Orthogonal arrays
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      – SubjectFull: Metrology
        Type: general
      – SubjectFull: Taguchi methods
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      – TitleFull: Optimization of Parameters of Block-Shaped Support Tooth Structure Using Orthogonal Experimental Design in Laser Powder Bed Fusion.
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              M: 04
              Text: Apr2026
              Type: published
              Y: 2026
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