
Influence of the Layer Thickness on the Dimensional Accuracy and Mechanical Properties of Lattice Structures During Laser Powder Bed Fusion of AlSi10Mg
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Lightweight design is a key trend in mechanical engineering, driven by both environmental responsibility and the goal of material and cost efficiency. By enabling load-specific and optimized structures, it reduces resource use and emissions. Additive Manufacturing (AM) supports this approach through its design flexibility and ability to produce complex, weight-efficient geometries. However, a big downside of the technology is the productivity of large-scale manufacturing in comparison to conventional manufacturing technologies. One of the critical parameters influencing the quality, productivity, and performance of PBF-LB-manufactured components is the layer thickness. A higher layer thickness accelerates manufacturing and reduces costs due to lower process times. On the downside, higher layer thicknesses may introduce dimensional inaccuracies, increased porosity due to incomplete fusion and surfaces roughness which ultimately compromises the component performance. While there are several studies about the influence of the layer thickness on bulk material, cellular materials like strut-based lattice structures are less investigated. In this study, the influence of the layer thickness on the geometrical dimensions, accuracy and surface roughness of the representative unit cells f2ccz and bcc is investigated. A preliminary study using a laser power–scan speed diagram for single contour exposures is performed to determine the processability window. Based on the resulting manufacturability, three layer thicknesses are selected for an in-depth parameter study with varying energy inputs. For each parameter set, characteristic geometrical features, such as strut diameter, strut diameter variation, waviness, and surface roughness, are systematically analysed. Moreover, density measurements are used to determine the influence of the layer thickness on the material porosity of the lattice structure. Finally, optimized parameter sets are selected, and both quasi-static compression and compression–compression fatigue tests are performed. The results highlight the influence of layer thickness not only on the mechanical performance of the lattice structures, but also on manufacturing productivity.