Aiming to improve the manufacturing accuracy of the build-in channels by selective laser melting (SLM), an anti-deformation model was established which was based on the simulation results of deformation and stress distribution of channel structure models with different length-depth ratios in SLM process by Simufact Additive software. It is demonstrated that the length of the channel structure is proportional to the deformation. Conversely, with the depth of the channel increases, the total distortion has a tendency of decreasing. The anti-deformation model can effectively reduce the amount of adhesive powder and deformation on the inner surface of printing parts, and improve the forming accuracy. In particular, the double-peak distortion occurs when the length and depth of the channel are 20 and 60 mm, respectively. Meanwhile, the roughness of overhanging surface is improved by 41.21% after compensating by anti-deformation mathematical model.

Laser rescanning technology is usually used to improve the forming quality of 3D printed parts. In order to investigate the relationship between rescanning strategy and forming quality, this paper proposed an interlayer rescanning strategy, which scans once at each odd-number layer and rescans at each even-number layer. In this work, 3D printed parts with inner structures were manufactured via selective laser melting. White light interference profilometry, scanning electron microscope, and three coordinates were used to analyze the surface quality, overhang sinking distance, and therefore the performance of samples with rescanning. White light interference profilometry-based roughness characterization revealed that the minimum surface roughness measured was 8.338 µm with rescanning and 9.676 µm with interlayer rescanning. The range of overhang sinking distance varied to a minimum of 0.146 mm with rescanning and 0.318 mm with interlayer rescanning. Based on the force analysis of the molten pool of overhang layers, the overhang sinking was mainly due to the increasing gravity of the molten pool and the insufficient supporting force provided by lower layers.

Surface texture has aroused widespread interest due to its role in controlling friction, reducing wear, and improving lubrication performance. As one of the most promising green processing technologies, Laser Powder Bed Fusion (LPBF) can manufacture complex structures, effectively reducing manufacturing constraints and significantly increasing structural design freedom. In this study, the powder bed model was established by numerical simulation, and the influence of different energy inputs on the morphology and characteristics of the molten pool was investigated. Based on this, the optimal forming process parameters of CuSn10 were selected. In addition, LPBF is used to process different textures (square texture, circular texture, hemispheric texture, and triangle texture) on the surface of CuSn10. The surface texture’s structural accuracy, surface morphology, and wettability were studied using a profiler, scanning electron microscope, and contact angle measuring instrument, respectively. The research results show that the accuracy of the square texture structure is the closest to the original design model among all the samples and the hemispheric texture surface does not have severe powder adhesion; as a result, it has the lowest average surface roughness of 5.58 µm. However, the triangle texture has the worst formation quality. It was revealed that the stepping effect mechanism of irregularly formed surfaces is the most important reason to cause this phenomenon. In addition, the maximum contact angle of the square texture is 85.59°, which is 15.76% higher than that of the triangle texture.