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.

This paper reports on a nested freeform Three Mirror Anastigmat (TMA) telescope designed for a 3U CubeSat, achieving a compact 1.5U form factor with a focal length of 500mm, F/4.6. Capable of near-diffraction-limited performance in a 0.37°x0.42° field of view, it provides 5m Ground Sampling Resolution in Low Earth Orbit. The paper explores two housing options: one for additive manufacturing (AM) and the other for conventional machining (CM), aiming to determine the optimal approach for creating an AM-based optical system housing suitable for space. The AM option offers lightweighting opportunities and enhanced structural integrity. The mirrors, manufactured in RSA 443 with Nickel Phosphorus plating, alongside the AM material, AlSi40, are discussed for their homogeneous coefficient of thermal expansion crucial for orbital conditions. The paper reports on the AM process, system metrology, and high precision finishing through Ion Beam Figuring.