Fig. 1. WE43 powder material. (a) Surface morphology of WE43 powder particles; (b) cross section of WE43 powder particle

Fig. 2. L-PBF formation chamber and auxiliary gas flow system

Fig. 3. Part design and scanning strategy sketches. (a) Design of thin rods with different diameters; (b) sketch of contour indentation; (c) sketch of size error and roundness error calculation; (d)-(g) design of porous scaffold units

Fig. 4. Cross sections of WE43 as-built parts under different L-PBF parameters. (a) P＝80 W, v＝800 mm/s; (b) P＝40 W, v＝1000 mm/s; (c) P＝120 W, v＝600 mm/s; (d) part deformation caused by immense energy input

Fig. 5. Formation quality of thin rods. (a) As-built thin rods; (b) cross section of thin rod; (c) relative density of each thin rode under different process parameters; size errors and roundness errors of rods under parameters of (d) 7#, (e) 13#, and (f) 18#

Fig. 6. Macro morphologies and surface morphologies of porous scaffolds (scale plate in optical photograph is 5 mm, and that in SEM image is 1 mm). (a)(b) SG; (c)(d) LG; (e)(f) D; (g)(h) BCC

Fig. 7. Morphologies and distributions of molten pools in L-PBF WE43 parts under different parameters. (a) Parameter of 13#; (b) parameter of 18#

Fig. 8. Microstructures of L-PBF as-built WE43. (a) Oxides observed at low magnification; (b) precipitated phase observed at high magnification; (c)-(h) element distributions corresponding to Fig. 8 (a)

Fig. 9. Tensile test results of L-PBF WE43. (a) Tensile curves and diagram of sample size; (b)(c) fracture surface morphologies of WE43 tensile samples (scale plate is 50 μm)

Fig. 10. Compression properties of different porous scaffolds. (a) Compression strength and elastic modulus; (b) compression curves