An Integrative Experimental Approach to Design Optimization and Removal Strategies of Supporting Structures Used during L-PBF of SS316L Aortic Stents
One of the fundamental challenges in L-PBF of filigree geometries, such as aortic stents used in biomedical applications, is the requirement for a robust yet easily removable support structure that allows each component to be successfully fabricated without distortion. To solve this challenge, an in...
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| Format: | Article |
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MDPI AG
2021-10-01
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| Series: | Applied Sciences |
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| Online Access: | https://www.mdpi.com/2076-3417/11/19/9176 |
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| author | Marius Grad Naresh Nadammal Ulrich Schultheiss Philipp Lulla Ulf Noster |
| author_facet | Marius Grad Naresh Nadammal Ulrich Schultheiss Philipp Lulla Ulf Noster |
| author_sort | Marius Grad |
| collection | DOAJ |
| description | One of the fundamental challenges in L-PBF of filigree geometries, such as aortic stents used in biomedical applications, is the requirement for a robust yet easily removable support structure that allows each component to be successfully fabricated without distortion. To solve this challenge, an integrative experimental approach was attempted in the present study by identifying an optimal support structure design and an optimized support removal strategy for this design. The specimens were manufactured using four different support structure designs based on the geometry exposed to the laser beam during the L-PBF. Support removal procedures included sand blasting (SB), glass bead blasting (GB), and electrochemical polishing (ECP). The two best-performing designs (line and cross) were chosen due to shorter lead times and lower material consumption. As an additional factor that indicates a stable design, the breaking load requirement to remove the support structures was determined. A modified line support with a 145° included angle was shown to be the best support structure design in terms of breaking load, material consumption, and manufacturing time. All three procedures were used to ensure residue-free support removal for this modified line support design, with ECP proving to be the most effective. |
| first_indexed | 2024-03-10T07:06:00Z |
| format | Article |
| id | doaj.art-b0d202aed73e489886f3b16891cd4140 |
| institution | Directory Open Access Journal |
| issn | 2076-3417 |
| language | English |
| last_indexed | 2024-03-10T07:06:00Z |
| publishDate | 2021-10-01 |
| publisher | MDPI AG |
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| spelling | doaj.art-b0d202aed73e489886f3b16891cd41402023-11-22T15:48:53ZengMDPI AGApplied Sciences2076-34172021-10-011119917610.3390/app11199176An Integrative Experimental Approach to Design Optimization and Removal Strategies of Supporting Structures Used during L-PBF of SS316L Aortic StentsMarius Grad0Naresh Nadammal1Ulrich Schultheiss2Philipp Lulla3Ulf Noster4Ostbayerische Technische Hochschule Regensburg, Galgenbergstrasse 30, 93053 Regensburg, GermanyOstbayerische Technische Hochschule Regensburg, Galgenbergstrasse 30, 93053 Regensburg, GermanyOstbayerische Technische Hochschule Regensburg, Galgenbergstrasse 30, 93053 Regensburg, GermanyOstbayerische Technische Hochschule Regensburg, Galgenbergstrasse 30, 93053 Regensburg, GermanyOstbayerische Technische Hochschule Regensburg, Galgenbergstrasse 30, 93053 Regensburg, GermanyOne of the fundamental challenges in L-PBF of filigree geometries, such as aortic stents used in biomedical applications, is the requirement for a robust yet easily removable support structure that allows each component to be successfully fabricated without distortion. To solve this challenge, an integrative experimental approach was attempted in the present study by identifying an optimal support structure design and an optimized support removal strategy for this design. The specimens were manufactured using four different support structure designs based on the geometry exposed to the laser beam during the L-PBF. Support removal procedures included sand blasting (SB), glass bead blasting (GB), and electrochemical polishing (ECP). The two best-performing designs (line and cross) were chosen due to shorter lead times and lower material consumption. As an additional factor that indicates a stable design, the breaking load requirement to remove the support structures was determined. A modified line support with a 145° included angle was shown to be the best support structure design in terms of breaking load, material consumption, and manufacturing time. All three procedures were used to ensure residue-free support removal for this modified line support design, with ECP proving to be the most effective.https://www.mdpi.com/2076-3417/11/19/9176aortic stentsfiligree structureslaser powder bed fusionadditive manufacturingSS 316Lsupporting structures |
| spellingShingle | Marius Grad Naresh Nadammal Ulrich Schultheiss Philipp Lulla Ulf Noster An Integrative Experimental Approach to Design Optimization and Removal Strategies of Supporting Structures Used during L-PBF of SS316L Aortic Stents Applied Sciences aortic stents filigree structures laser powder bed fusion additive manufacturing SS 316L supporting structures |
| title | An Integrative Experimental Approach to Design Optimization and Removal Strategies of Supporting Structures Used during L-PBF of SS316L Aortic Stents |
| title_full | An Integrative Experimental Approach to Design Optimization and Removal Strategies of Supporting Structures Used during L-PBF of SS316L Aortic Stents |
| title_fullStr | An Integrative Experimental Approach to Design Optimization and Removal Strategies of Supporting Structures Used during L-PBF of SS316L Aortic Stents |
| title_full_unstemmed | An Integrative Experimental Approach to Design Optimization and Removal Strategies of Supporting Structures Used during L-PBF of SS316L Aortic Stents |
| title_short | An Integrative Experimental Approach to Design Optimization and Removal Strategies of Supporting Structures Used during L-PBF of SS316L Aortic Stents |
| title_sort | integrative experimental approach to design optimization and removal strategies of supporting structures used during l pbf of ss316l aortic stents |
| topic | aortic stents filigree structures laser powder bed fusion additive manufacturing SS 316L supporting structures |
| url | https://www.mdpi.com/2076-3417/11/19/9176 |
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