###### Abstract  
One of the fundamental challenges in L-PBF of filigree geometries, such as aortic stents used in biomedical applications, is the requirement for a robust yet easily removable support structure that allows each component to be successfully fabricated without distortion. To solve this challenge, an integrative experimental approach was attempted in the present study by identifying an optimal support structure design and an optimized support removal strategy for this design. The specimens were manufactured using four different support structure designs based on the geometry exposed to the laser beam during the L-PBF. Support removal procedures included sand blasting (SB), glass bead blasting (GB), and electrochemical polishing (ECP). The two best-performing designs (line and cross) were chosen due to shorter lead times and lower material consumption. As an additional factor that indicates a stable design, the breaking load requirement to remove the support structures was determined. A modified line support with a 145\({}^{\circ}\) included angle was shown to be the best support structure design in terms of breaking load, material consumption, and manufacturing time. All three procedures were used to ensure residue-free support removal for this modified line support design, with ECP proving to be the most effective. aortic stents; filigree structures; laser powder bed fusion; additive manufacturing; SS316L; supporting structures; optimization +
Footnote †: journal: Applied Sciences  
article  
[color=gray!20,color=gray!20,color=gray!manufacturing can be done in a relatively short amount of time while still meeting the specifications of the finished product. L-PBF is a potential AM approach for achieving near-net shaping of components by depositing a powder layer of a certain thickness and then utilizing a laser source to fuse selective regions within the powder bed according to slices defined by an input 3D model. When compared to other AM processes such as wire arc additive manufacturing (WAAM) [7; 8], L-PBF is by far one of the most dependable AM routes for fabricating complicated geometry components with surface roughness dictated by powder particle size, resulting in less post-processing. The L-PBF process has also resulted in mechanical properties that are superior to casting [9]. Nonetheless, the repeated melting and solidification during the L-PBF process, as well as the associated residual stress generation, could result in delamination during manufacturing or distortion after removal from the support plate [10]. The design freedom available when employing L-PBF AM to fabricate metallic components is limited due to the inherent residual stress generation during manufacturing. Furthermore, the layer-by-layer fabrication of filigree structures can result in distinct traces in subsequent layers [11]. As a result, additional support structures are needed to manufacture filigree structures using the L-PBF method [12]. Support structures can serve a variety of purposes depending on the AM method used [11]. Support structures are critical for a product's manufacturability, particularly when the geometry is complex, such as in filigree structures [13; 14]. When there are overhanging elements, support structures are required for balancing the portion [15]. Support structures also serve as a heat sink and provide less constraint, resulting in lower residual stresses [16]. Incorporating support structures during L-PBF, on the other hand, can result in additional material, time, and energy usage. As a result, there is a cost connected with this and optimizing the support structure design based on the unique application requirement is critical. Furthermore, the included support structures must be eliminated from the finished product in the most efficient and cost-effective manner possible. Hence, support structure optimization and support removal strategies need to be considered as a union of a function that optimizes the manufacturability of a filigree structure using L-PBF.