随着机械系统复杂性的不断增加，在现代结构理论模型的设计中，设计者需要统筹考虑结构新颖性、性能优良性和制造可行性，但传统的制造方式对设计约束很大。选区激光熔化（SLM）是快速制造中最有发展潜力的技术之一，在理论上可以实现任意复杂的计算机辅助设计（CAD）理论模型到金属功能件的直接制造。针对SLM自由制造的特点，结合华南理工大学在该技术方面的研究基础，研究了具有免组装、功能集成和轻量化特点的复杂金属功能件自由设计与直接制造的工艺，为航空航天、医疗、汽车等领域的产品创新设计与个性化制造提供参考。

As the complexity of the mechanical system is increasing, designers need to give comprehensive consideration to the novelty, excellent performance and manufacturing feasibility of the structure in the design of the theoretical model of modern mechanism. However, the traditional manufacturing methods impose great restriction on the design. Selective laser melting (SLM) is one of the technologies that have most development potential, which can achieve direct manufacturing of metal functional parts from any complex computer-aided design (CAD) theoretical models in theory. Based on the characteristics of the freeform manufacturing of SLM, combining with the related research of South China University of Technology, we study the freeform design and direct manufacturing process of complex metal pieces with non-assembly, functional integration and lightweight characteristics, which provides effective reference for the innovative design and personalized manufacturing of products in the fields of aerospace, medical treatment and automobile.