Supplementary material to publication with title: Design Guidelines for Laser Powder Bed Fusion of Triply Periodic Minimal Surface Structures for Applications in Smart Reactors. - Project: SFB1615 - Subproject: C01-Integration of components into adaptive geometries

This study investigates the design and manufacturability of TPMS structures using 316L stainless steel via PBF-LB/M, focusing on the interaction of key parameters: porosity, unit cell size, and sheet thickness, of which two are independent variables while the third is a dependent variable. Through numerical simulations, experimental validation, and process optimization, practical design guidelines are developed. The design parameters of Gyroid-TPSf and Schwarz-Diamond-TPSf samples include porosities ranging from 70 % to 90 % and unit cell sizes from 2 mm to 20 mm. The results indicate that specifically, at large unit cell sizes (e.g., 20 mm), the decreased curvature radius reduces self-supporting effects, leading to insufficient mechanical stability during printing and resulting in local deformation. Conversely, at small unit cell sizes combined with high porosity levels (e.g., 2 mm and 90 %), the sheet thickness becomes critically thin, often below the printable resolution, resulting in incomplete or fragile structures.