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<p>Powder bed fusion (PBF) is an Additive Manufacturing (AM) technique that employs localized laser energy to fuse metallic powders in a layer-by-layer manner to construct a 3D object. Aside from the high design freedom in the shape, the technology is constrained by the need for support structures, particularly for low-angle overhangs. These unsupported areas are prone to significant residual stresses, and surface defects, such as warpage and dross formation, primarily owing to poor heat dissipation and rapid solidification. In view of this, this review critically examines the current body of the published literature focused on support-free PBF printing and the mechanisms underlying overhang printability. The bibliometric review was conducted on the literature related to the topic of support-free printing on Web of Sciences database between 2008 and 2025. From the limited number of publications, it can be observed that most concentrate on optimization of the downskin printing, while some others explore the alternative solutions. Nevertheless, there is a lack of systematic and repeatable strategy for reliable support-free printing. In conclusion, this paper consolidates scattered information to provide a theoretical foundation for PBF overhang challenges, outlines different strategies for achieving support-free printing, and presents selected case studies to serve as inspiration for practitioners printing metal components with PBF.</p>

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A review on support-free printing with powder bed fusion method

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年9月30日

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  • Jiri Hajnys,
  • Quoc-Phu Ma,
  • Radoslav Vandzura,
  • Matus Gelatko,
  • Jakub Mesicek,
  • Jana Petru,
  • Marek Pagac

摘要

Powder bed fusion (PBF) is an Additive Manufacturing (AM) technique that employs localized laser energy to fuse metallic powders in a layer-by-layer manner to construct a 3D object. Aside from the high design freedom in the shape, the technology is constrained by the need for support structures, particularly for low-angle overhangs. These unsupported areas are prone to significant residual stresses, and surface defects, such as warpage and dross formation, primarily owing to poor heat dissipation and rapid solidification. In view of this, this review critically examines the current body of the published literature focused on support-free PBF printing and the mechanisms underlying overhang printability. The bibliometric review was conducted on the literature related to the topic of support-free printing on Web of Sciences database between 2008 and 2025. From the limited number of publications, it can be observed that most concentrate on optimization of the downskin printing, while some others explore the alternative solutions. Nevertheless, there is a lack of systematic and repeatable strategy for reliable support-free printing. In conclusion, this paper consolidates scattered information to provide a theoretical foundation for PBF overhang challenges, outlines different strategies for achieving support-free printing, and presents selected case studies to serve as inspiration for practitioners printing metal components with PBF.