Laser Powder Bed Fusion - Principles, Challenges, and Opportunities

Laser Powder Bed Fusion (L-PBF) is an additive manufacturing process which uses a scanning laser beam to selectively melt metal powder in a layer-wise manner to produce solid metal parts. In comparison to conventional subtractive or formative manufacturing processes, L-PBF imposes few design constraints on part geometry and requires low setup effort without the requirement for custom tooling. These unique capabilities enable the manufacture of complex parts that are highly customizable. A broad range of metals can be processed provided they are in a specific powdered form, and that they meet the process compatibility requirements associated with laser weldability. L-PBF provides an exciting opportunity for the manufacture of novel devices for chemical engineering applications, previously difficult or infeasible with conventional manufacturing processes including, cellular materials, high-efficiency heat exchangers, and reactors with highly optimised geometry. To utilize this technology to its maximum potential, it is necessary to understand the practical technological benefits as well as the operational constraints associated with L-PBF materials, process characteristics, part design, and suitable application areas. Particularly, as the final part quality is determined by many influential parameters. The following chapter provides an overview of L-PBF to assist designers in optimizing the functional performance, manufacturability, reliability, and cost of additively manufactured products.