Enabling miniature functional mechanical component assemblies in metal using conventional laser powder bed fusion equipment

Laser Powder Bed Fusion (LPBF) is a widely used Additive Manufacturing (AM) technique for processing various types of metals by selectively scanning metal powder particles in a layer-by-layer fashion with a focused laser beam. A large majority of LPBF components manufactured nowadays are relatively large in size, with typical outer dimensions of several centimetres up to about 50cm. Smaller parts, and more specifically as-printed assemblies of several connected small parts, however, do typically have a higher added value to cost ratio compared to single large components. Indeed, smaller parts require less powder, less production time, and – when integrated in as-printed functional assemblies – also less post-manufacturing steps. The complexity in miniature LPBF part manufacturing is situated in the need for a well-balanced selection of four important and highly interlinked aspects for a given material, namely: (i) design, (ii) LPBF parameters for small features, (iii) machine specifications, and (iv) post-manufacturing needs. This PhD research aims to address this by researching new strategies for design and for LPBF process optimisation to enable miniature functional mechanical assemblies in a given material and produced on conventional laser powder bed fusion equipment. The resulting insights, limitations and opportunities should enable more and better LPBF manufacturing of miniature functional mechanical component assemblies.