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About this Abstract
Meeting 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Symposium 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Presentation Title Effects of Computer-Generated Beam Profiles on Melt Pool Geometry and Part Density in PBF-LB/M of IN718: From Simulation-Based Optimization to Volumetric Parts
Author(s) Richard Off, Vijaya Holla, Jonas Grünewald, Katrin Wudy
On-Site Speaker (Planned) Richard Off
Abstract Scope Laser beam shaping can improve productivity and process stability in laser-based powder bed fusion of metals (PBF-LB/M). So far, mainly simple, rotationally symmetric beam profiles have been investigated, while the influence of complex, non-rotationally symmetric beam profiles on volumetric part properties remains largely unexplored. This study investigates three computer-generated beam profiles, targeting a rectangular melt pool cross-section, a Gaussian-like melt pool cross-section with reduced peak temperature, and a homogeneous melt pool temperature distribution. Cube specimens are manufactured with varied laser power and scan speed and analyzed by Archimedean density measurements and metallographic cross-sections. All three profiles result in wide process windows with relative Archimedean densities ≥ 99.0 %, while quadrupling the build rate of a state-of-the-art reference process using a Gaussian beam profile. The simulated steady-state melt pool depth correlates with the measured densities. Remaining challenges are a coarser solidification structure and a waviness propagating through the part.
Proceedings Inclusion? Planned: Post-meeting proceedings

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