Effect of pre-heat temperature on enhancing the processability of pure zinc by laser-based powder bed fusion

Zinc-based biomaterials are promising for bioresorbable applications; however, their low melting points pose challenges in laser-based additive manufacturing (AM). This study addresses this challenge by focusing on pre-heat temperature in laser-based powder bed fusion (PBF-LB) AM, a critical factor that significantly impacts final part properties. Unlike previous studies, this work systematically explores the pre-heat temperature’s role in shaping the process map, alongside laser power and scanning speed, for high-density zinc fabrication. The primary goal is to analytically generate parameter sets to avoid the vaporization temperature of zinc during the PBF-LB process and enhance the process’s stability. The proposed approach demonstrates a significant influence of the variation in pre-heat temperature on other input parameters range, such as power and scanning speed, thus enhancing the material’s processability both theoretically and next experimentally. For model validation, 20 specimens divided between three builds each with unique pre-heat temperatures were printed, revealing a direct correlation between increased pre-heat temperature and part density. Remarkably, high density was achieved even with low laser power and high scanning speed, reaching up to 99.96%. This emphasizes the role of pre-heat temperature in enhancing production speed without compromising part integrity. Mechanical properties, assessed by Vickers microhardness (31.4 ± 3.5–39.7 ± 3.3 HV). Control over pre-heat temperature shows promise in influencing part microstructure and grain morphology, critical for future studies.