CMN 2026

A Computational Framework for Inclination-Aware Process Parameter Mapping in PBF-LB/M

  • Giannetto, Domenico (Universidad de Navarra, TECNUN Escuela de Ing)
  • Ghouse, Shaaz (Imperial College London)
  • Rodriguez-Florez, Naiara (Universidad de Navarra, TECNUN Escuela de Ing)
  • Ruiz de Galarreta, Sergio (Universidad de Navarra, TECNUN Escuela de Ing)

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The fabrication of complex porous architectures by Metal Laser Powder Bed Fusion (PBF-LB/M) is strongly affected by local surface inclination, which governs heat dissipation, melt-pool stability, and defect formation. Commercial PBF-LB/M software typically identify downskin regions based on a single critical surface-inclination threshold and assign a unique laser parameter set to all such regions, limiting effective process control for complex, micrometric and thin-walled structures such as triply periodic minimal surfaces (TPMS). This study investigates how experimentally validated PBF-LB/M parameters can be systematically mapped to locally varying surface inclinations while preserving manufacturability and mechanical integrity. A computational design framework was developed to enable inclination-aware parameter assignment in wall-based porous structures through single-contour strategies. The framework was applied to Gyroid geometries, a TPMS structure widely explored in biomedical, aerospace, and automotive fields. Mesh surfaces of such architectures were segmented by local face inclination and exported as toolpath data to assign distinct laser power–scan speed combinations to each inclination range. Compared to default-printed specimens, the proposed workflow resulted in improved surface quality and thickness uniformity, yielding mechanical responses closer to numerical predictions and demonstrating its relevance for small-scale TPMS structures with stringent mechanical and geometric requirements in biomedical, lightweight energy-absorbing, and heat-exchange applications.