Abstract:Due to excellent thermal conductivity and electrical conductivity, copper materials have important application value in key fields such as efficient heat sinks and microwave RF connectors. Aiming at breaking through the bottleneck that the traditional casting process struggles to produce complex fine structures, this study adopted laser powder bed melting (LPBF) technology. Based on the optimized process parameters established in the previous work, the formability and design principles of typical geometrical shapes of oxygen-free copper prepared by LPBF process, including thin-wall grille and overhanging structures, were analyzed and discussed. The results showed that LPBF successfully prepared thin-wall grille structure with thickness range of 0.1~1.0 mm, circle overhanging structure with an aperture range of Φ 0.4~2 mm and overhanging structure at an angle to the horizontal plane of 15° and 30°. Characterization test and mechanism analysis showed that the high thermal conductivity of copper promoted rapid solidification of the molten pool, effectively inhibiting melt flow within the limited molding height, and reduced the overhanging angle without causing hanging slag and collapse. This breakthrough overcame the traditional process constraints requiring support structures for overhanging formations. The research findings provided theoretical guidance for rapid manufacturing of copper thin-wall grilles and overhanging components, and laid a theoretical foundation for industrial production applications.