Development of geometric-adaptive parameters for support-free 3D printing (LPBF) of Inconel 718

3D metal printing has transformed the manufacturing of complex components for high performance in extreme environment such as space and aerospace. However, the current constraint of 45° overhang angle limits the potential of metal 3D printing. This dissertation presents an unconventional and novel framework to circumvent these current limitations in LPBF. In particular, this thesis presents the world-first process map for 1st layer overhang, followed by the novel breakthrough of defect-free horizontal overhangs without support. Novel understanding of the melt pool dynamics in both spatially and temporally resolved manner enables the printing of complex components such as Ni-based superalloy turbine blade without support.