With the growing acceptance of additive manufacturing (AM) across various sectors, laser-based powder bed fusion (PBF-LB) has widely been utilized to create intricately shaped parts from a range of metals alloys. The factors contributing to this reception are limited not only to the achievable geometrical complexity but also enhanced product functionality. Prominent sectors such as aerospace, defense, and biomedical have begun to leverage PBF-LB for a wide range of applications; its use in other industries, such as cutting tool manufacturing, remains more limited. Therefore, to address the potential of LPBF for higher performance in cutting tool applications, this study examines topology optimization and the laser powder bed fusion of face mills with experimental modal characteristics and cutting performance. The objectives in topology optimizations were to decrease the vibration magnitudes of face mills while keeping them stiff against deformation due to cutting forces. Three distinct designs were benchmarked, each with different weight reduction targets, and were fabricated using PBF-LB with M300 maraging steel. The optimized face mills demonstrated better performance with diminished vibration magnitudes and less tool wear patterns.

Additive manufacturing (AM) enables the consolidation of components and the integration of new functionalities in metallic parts, but layered fabrication often results in poor surface quality and geometric deviations. Among various surface treatment techniques, machining is often favoured for its capability to enhance not only surface finish but also critical geometric tolerances such as flatness and circularity, in addition to dimensional accuracy. However, machining AM components, particularly thin-walled structures, poses challenges related to unconventional material properties, complex fixturing, and heightened susceptibility to chatter. This study investigates the vibrational behaviour of thin-walled Ti6Al4V components produced via laser powder bed fusion, using a jet-engine compressor blade demonstrator. Four stock envelope designs were evaluated: constant, tapered, and two topologically optimised variants. After fabrication by Laser Powder Bed Fusion, the blades underwent tap testing and subsequent machining to assess changes in modal characteristics. The results show that optimised geometries can enhance modal performance without increasing the volume of the stock material. However, these designs exhibit more pronounced in situ modal changes during machining, due to greater variability in material removal and chip load, which amplifies vibration sensitivity compared to constant or tapered stock designs.