The aim of this paper was to investigate the compression properties of several trabecular structures produced by additive laser manufacturing of a Ti6Al4V, having different densities and unit cells. Filling space structures were investigated, with different unit cells characterized by both bending-dominated and stretching-dominated behaviour. The stiffness and yield strength were correlated to relative density according to the Gibson and Ashby model. For a constant porosity, the stiffness and the yield strength varied between two extremes represented by the cubic structure (stretching-dominated deformation) and the cross structure (bending-dominated deformation). The properties of the deformed structures did not differ substantially from those of the regular structures. Only in the cubic structure did distortion enhance the contribution of bending to deformation and both stiffness and strength decreased. Cross structures displayed the highest strength at constant stiffness than the others, since they are characterized by the most favourable orientation of the struts.

The microstructure and mechanical properties of 17-4 stainless steel produced by Binder Jetting (BJT) and heat treated according to the standard conditions for the 17-4 PH steel (H900 and H1100) were investigated. The sintered relative density is 97.8% with a slightly anisotropic shrinkage. Tensile strength and elongation are above the minimum required for the wrought steel and comparable to those of the same material manufactured by Metal Injection Molding. They are also better than those reported in the literature for the 17-4 PH stainless steel manufactured by BJT. Tensile elongation at fracture is anisotropic, highlighting a significant dependence of the non-uniform plastic deformation on the direction.

In this chapter, a three-dimensional finite element model is developed to simulate the thermal behavior of the molten pool in selective laser melting (SLM) process. Laser-based additive manufacturing (AM) is a near net shape manufacturing process able to produce 3D objects. They are layer-wise built through selective melting of a metal powder bed. The necessary energy is provided by a laser source. The interaction between laser and material occurs within a few microseconds, hence the transient thermal behavior must be taken into account. A calibration procedure is carried out to fit the numerical solution with the experimental data. Once the calibration has corrected the thermal parameters, a dynamic mesh refinement is applied to reduce the computational cost. The scanning strategy adopted by the laser is simulated by a path simulator built using MatLab®, while numerical analysis is carried out using ANSYS®, a commercial finite element software. To improve the performance of the simulation, the two codes interact each other to solve the analysis. Temperature distribution and geometrical feature of the molten pool under different process conditions are investigated. Results from the FE analysis provide guidance for setting up the optimization of process parameters and develop a base for further residual stress analysis.