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Laser-based additive manufacturing (AM) of Ti-6Al-4V has become increasingly important for use in components of transportation devices. The most significant advantage over conventional steel structures is the reduction in specific weight. Complex geometries can be produced with the layer-by-layer manufacturing process and the personalised, unique part production can be faster and produced with the lower costs and less material waste than the conventional manufacturing techniques. Between the manufacturing process of an additively manufactured part and its use, the post-processing is an essential factor related to the strength properties or porosity of the finished product. The heat treatment is a possibility to change the final part properties.

Additive manufacturing provides the possibility to print complex generative designed bodies. The research deals with redesigning a payload part of a camera holder using generative design for selective laser melting. The possibility of replacing the original polymer component with a metal printed component of a greater strength and the effect of different parameters of generative design were investigated. By comparing the generative design results obtained in several phases, the goal was to find a solution that can be used to replace the previous part and become printable with 3D metal printing. The internal stress values for each case and the amount of weight reduction that can be achieved were determined. With the results obtained, the parts were prepared for printing. It is the key aspect of the industrial application of generative optimization.

3D printing of metal parts was investigated in this research work, which connecting to the supporting of model. The connection between the support and the model is important form the viewpoint of the mechanical fixturing, the heat conduction, the removability of the support and the success of printing. In this research work, some support and tooth parameters such as the top length, the hatch distance, and base length, tooth height were investigated to create a model-support connection strength map. This knowledge makes it possible to select the most appropriate connection type between the support and the model by the requirements specified in different cases. The strength of the support-model connection was characterized by the shearing properties using the torsion test. The results are illustrated and compared by different support parameters and materials. The 316L stainless steel and Ti6Al4V alloy were investigated.

In Selective Laser Melting technology, the deformation of a metal model depends on many parameters. A complex model geometry needs simulation software to compensate for it. In this research work, the different types of model geometries, materials (316L, Ti64), and pre-deformation processes were analyzed in a Selective Laser Melting dedicated simulation software and the real model. The result shows the geometrical difference between the standard and the pre-deformed models and the simulated results and printed parts. Due to the result, the necessity of pre-deformation, the right choice of simulation parameters, and the simulation process become more understandable and predictable in SLM technology. Of the two raw materials, in the case of titanium, higher internal stresses are generated during printing, so knowing what the deformations are is even more important than in the case of steel. An important result of the research is that it clearly demonstrates where and to what extent deformation occurs in the case of post-printing operations, thus the desired geometry can better meet the requirements.