Optimization of supports removal in AlSi10Mg components for improved SLM processes

Additive manufacturing is a family of manufacturing processes that create components in a layer by layer approach directly from the CAD data. It has enabled the production of new and innovative designs, impossible to manufacture with standard subtractive processes. Selective laser melting processes work with metals and can achieve fully dense components but require the addition of support structures. These structures are necessary for mechanical and thermal reasons to correctly create the components, avoid warping and minimize deformations. They are made of the same material as the component being built and due to this, they may be very challenging to remove without damaging the part. This work aims at investigating the feasibility of support removal with sandblasting in components produced with laser powder bed fusions machines from the aluminum alloy AlSi10Mg. The optimization process to achieve this objective involved two different aspects: •??a study of the geometrical parameters of the support structure to minimize the solid parts and creating weaker structures, enabling a more effective abrasive media flow through the support and removal of it. •??a study on the process parameters used to manufacture the support structure, to weaken their material by creating a not fully dense metal with pores and imperfections to aid sandblasting. Moreover, research has been conducted on industrial processes available on the market to post-process components produced by laser powder bed fusion, to evaluate their effectiveness at removing the support structure and their financial feasibility. This creates an extensive overview of post-processing approaches that enable companies operating in the sector to make more informed decisions about this part of the metal additive manufacturing production chain.