Abstract
Electron-beam melting (EBM) is a rapidly developing metal additive manufacturing (AM) method. It is more effective with complex and customized parts manufactured in low volumes. In contrast to traditional manufacturing, it offers reduced lead time and efficient material management. However, this technology has difficulties with regard to the construction of overhang structures. Production of overhangs using EBM without support structures results in distorted objects, and the addition of a support structure increases the material consumption and necessitates post-processing. The objective of this study was to design support structures for metal AM that are easy to remove and consume lower support material without affecting the quality of the part. The design of experiment methodology was incorporated to evaluate the support parameters. The multi-objective optimization minimizing support volume and support removal time along with constrained deformation was performed using multi-objective genetic algorithm (MOGA-II). The optimal solution was characterized by a large tooth height (4 mm), large tooth base interval (4 mm), large fragmented separation width (2.5 mm), high beam current (6 mm), and low beam scan speed (1200 mm/s).