Novel path planning algorithm for laser powder bed fusion to improve the scan quality of triply periodic minimal surface structures

Abstract

Traditional path planning methods, such as contour and raster methods, suffer from problems like uneven filling, overfilling, and underfilling in the sliced layers, resulting in poor continuity of the lattice melt pool, internal porosity defects, and severe powder adhesion at the contour edges, while research on path planning for three-periodic minimal surfaces lattices is relatively limited. In this study, a scanning path planning method based on lattice equations control is proposed, which differs from traditional contour paths and raster paths. The new paths are controlled by the isosurface parameters of the lattice equation and optimized using the traveling salesman problem, resulting in more uniform scanning paths. The new paths avoid the underfilling issue present in raster path and the sawtooth-shaped borders of raster path. Additionally, they circumvent the nonuniform scanning path problem caused by uneven wall thickness in contour path. Through visualizing the paths and conducting printing experiments on the lattice, it is found that the new path is more uniform compared to contour paths, effectively addressing the issue of overfilling. Compared to raster paths, the new path has smoother boundaries and reduces internal porosity and powder adhesion within the lattice. This research has important value in reducing internal porosity and external powder adhesion issues in three-period minimal surface (TPMS) lattice printing processes, further enhancing the manufacturing quality of TPMS lattices.