Support structures are essential to laser powder bed fusion (PBF-LB/M). They sustain overhangs,
prevent distortion, and dissipate process-induced heat. Their removal after manufacturing is
required, though, increasing the overall costs. Therefore, optimization is important to increase
the economic efficiency of PBF-LB/M. To enable optimization focused on the support
structures’ costs, a cost model is developed. The whole production process, including the design,
manufacturing, and post-processing of a part is considered by deriving formulas for the
individual costs. The cost model is applied to a benchmark procedure previously developed.
Additionally, a case study investigating different support layout strategies is conducted.Mechanical Engineerin
