New Calculation Software for Analytic Support Structure Optimization in Metal Additive Manufacturing

Powder based additive manufacturing systems often require support structures for overhanging geometries and thermal dissipation. On the one hand, the support material should be reduced to a minimum. On the other hand, the stiffness of the structures can be used as a fixture for post-processing. The contribution presents a unique analytic model to determine the stresses occurring in the support structures during post-processing. FEM simulations with different support types are carried out to validate the new calculation model. The results of this analysis subsequently serve as basis for dimensioning the support elements of complex and large parts. By specifying a machining process, it is possible to determine the required dimensions of the support structure (e.g. block, rod or cross). The aim of this optimization process is to reduce machining time, material consumption and post-processing costs. The results of the paper and the new software help to implement direct machining into industrial 3D printing processes.