Hybrid manufacturing enables to overcome additive manufacturing (AM) constraints regarding the maximum feasible part dimension and/or complexity through part separation and subsequent adhesive joining of AM sub-parts. To ensure structural integrity of the joint at a minimum use of substrate volume, the AM inherent freedom of design can be exploited by realizing 3D micro scarf adhesive joints. The performance of this novel adhesive joint design was assessed by conducting optical measurements and static tensile tests using samples fabricated by laser-based powder bed fusion of metals (PBF-LB/M).

The topic of support structure design in the Design for Additive Manufacturing (DfAM) field is not addressed with the same relevance as the topic of part design. Therefore, this contribution investigates parameters for both the manufacturing and support structure design for the Laser Powder Bed Fusion (L-PBF) process. Matrices for cause-effect-relations of manufacturing and design parameters on build properties as well as correlations of them are presented. Based on these, recommendations for actions for experimental procedures are derived following the Design of Experiments method.