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<p>The fabrication of complex lattice structures, such as triply periodic minimal surfaces (TPMS), using Laser Powder Bed Fusion (LPBF) remains challenging due to geometric inaccuracies and surface irregularities. These issues are mainly governed by the processing parameters of the skin and contour exposure elements, which play a decisive role in defining external geometries, particularly in small-scale or intricate structures. This study investigates the influence of laser power, scanning speed, and spot size within the skin and contour elements to improve dimensional accuracy and minimize surface roughness in AlSi10Mg TPMS structures. A two-stage experimental approach was employed: in the first stage, a Central Composite Design (CCD) was used to evaluate the individual effects of each parameter on skin and contour elements independently, followed by a full factorial design to analyze their combined influence. Results indicate that spot size plays a critical role in both surface roughness and wall thickness. Smaller spot sizes (&lt; 100&#xa0;μm) improve surface quality, while larger spot sizes (&gt; 150&#xa0;μm) promoted greater dimensional stability in the contour. This study proposes processing conditions that enhance the manufacturability and geometric reliability of TPMS structures, thereby supporting their broader implementation in aerospace, biomedical, and energy applications.</p>

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Improvement of LPBF aluminium TPMS fabrication: effect of process parameter on skin and contour exposure elements

  • 期刊论文

  • 发表日期：

    2025年11月18日

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  • Carolina Ortega-Portilla,
  • Haideé Ruiz-Luna,
  • Juan Manuel Gonzalez-Carmona,
  • Christian Felix-Martinez,
  • Arturo Gómez-Ortega

摘要

The fabrication of complex lattice structures, such as triply periodic minimal surfaces (TPMS), using Laser Powder Bed Fusion (LPBF) remains challenging due to geometric inaccuracies and surface irregularities. These issues are mainly governed by the processing parameters of the skin and contour exposure elements, which play a decisive role in defining external geometries, particularly in small-scale or intricate structures. This study investigates the influence of laser power, scanning speed, and spot size within the skin and contour elements to improve dimensional accuracy and minimize surface roughness in AlSi10Mg TPMS structures. A two-stage experimental approach was employed: in the first stage, a Central Composite Design (CCD) was used to evaluate the individual effects of each parameter on skin and contour elements independently, followed by a full factorial design to analyze their combined influence. Results indicate that spot size plays a critical role in both surface roughness and wall thickness. Smaller spot sizes (< 100 μm) improve surface quality, while larger spot sizes (> 150 μm) promoted greater dimensional stability in the contour. This study proposes processing conditions that enhance the manufacturability and geometric reliability of TPMS structures, thereby supporting their broader implementation in aerospace, biomedical, and energy applications.