Benchmark parts for the evaluation of optimized support structures in laser powder bed fusion of metals

Laser powder bed fusion (PBF-LB/M) of metals belongs to the advanced additive manufacturing processes on the brink of industrialization. Successful manufacturing often requires the utilization of support structures to support overhangs, dissipate heat, and prevent distortion due to residual stresses. Since the support structures result in increased costs, research, as well as industry, aim at optimizing the application of those or the support structures themselves. New approaches are validated with individual use cases, though, preventing an objective comparison of optimization strategies. This paper contributes to the advance of support structure optimization by providing a benchmark strategy including part geometries, which enables to evaluate technical as well as economical aspects of support structures or support strategies. The benchmark process is demonstrated with the help of the currently most used block and pin support structures.