Grid-tree composite support structures for lattice parts in selective laser melting

Metal lattice structure has excellent mechanical properties to develop lightweight parts, and selective laser melting (SLM) makes it possible to construct complex lattice parts without molds. Support structures are required in SLM to remove heat away from the process and reduce geometrical distortions. However, traditional support structure generation methods have some problems, such as low generation efficiency, difficulty in the removal and not meeting the fabrication requirements of lattice parts. Therefore, this article proposes a grid-tree composite support structure generation algorithm for lattice parts. First, optimize the build orientation of the lattice parts considering the surface quality of functional features and the processability of lattice structures. Then, identify the frame’s overhang area and the point overhang of lattice structures. Finally, generate the grid-tree composite support structure for lattice parts. We conducted experiments to verify our approach and compare our method with three supports of Magics RP. Experimental results reveal that our method is effective in reducing support volume and warpage deformation.