Supplementary material to publication with title: On resource efficient and individualized tree support structures for PBF-LB/M by process simulation

This dataset is supplementary material to the publication with the title "On resource efficient and individualized tree support structures for PBF-LB/M by process simulation" of the Fraunhofer Direct Digital Manufacturing Conference (DDMC) 2025, 12 – 13 March 2025, Berlin/Germany. The corresponding paper investigates a novel approach combining numerical process simulation with a user-friendly software tool to design resource-efficient tree support structures. A demonstrator part, manufactured from Ti6Al4V titanium ally, was used to validate the effectiveness of these generative support designs. The accuracy of the process simulation was assessed by comparing numerical results with geometrical displacements, obtained by 3D scanning the additively manufactured demonstrator parts. Additionally, the newly designed support structures were compared against widespread block supports, focusing on material consumption and geometrical precision. The results demonstrate that the presented approach allows for the creation of individualized and efficient support structures, leading to faster print preparation and reduced manufacturing costs. Moreover, new and promising manufacturing limits for thin rods in PBF-LB/M were identified in a parameter study. Overall, the integration of advanced support design techniques shows promise for enhancing the sustainability and cost-effectiveness of PBF-LB/M.