Executive Summary : | stainless steel is increasingly used in the manufacturing industry for biomedical implant products, such as tooth implants, surgical scissors, bone replacement, and heart valves. The manufacturing process for ss316L bio-implants is complex and has limitations due to the increasing number of musculoskeletal illnesses and injuries. The laser powder bed fusion (LPBF) process is a promising solution, offering capabilities in 3D printing intricate designs, fine-tuning material properties, tight tolerance, and lattice structures. However, rapid melting and solidification can lead to defects like residual stress, cracking, and heat accumulation. To mitigate these issues, careful fine-tuning of LPBF process parameters is necessary. The production rate of LPBF implants is also a challenge due to factors like support structures removal, smaller built volume, reduced number of implants, and additional machine setup time. A robust methodology is needed to address material wastage and the presence of support structures, ensuring defect-free implant products. This work aims to optimize input process parameters, formulate advanced parametric algorithms, and develop a novel methodology to fabricate support-free structures without compromising mechanical integrity in the LPBF process. |