Process and geometrical integrity optimization of electron beam melting for copper

This work systematically analyzes and optimizes the process of electron beam melting for pure copper. It is shown that, for reliable manufacturing, the preheating temperature should be optimized to avoid porosity as well as part deformation. The electron beam should be fully focused to prevent shrinkage voids (correlated to negative defocusing) and material spattering (linked to positive defocusing). Smoother surfaces from lower hatch spacing (e.g., 100µm) can improve the density reliability, while longer overhangs are reached by a higher hatch spacing. A suitable starting contour strategy is also applied to mitigate border porosities, reduce side roughness and increase geometric precision.