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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, Philipp Kopp, Stefan Kollmannsberger, Katrin Wudy
On-Site Speaker (Planned) Richard Off
Abstract Scope Inversely designed beam profiles allow tailoring laser intensity distributions in laser-based powder bed fusion of metals towards prescribed melt pool characteristics. However, such beam profiles have been investigated exclusively under single-track conditions. This study demonstrates how volumetric processing affects melt pool characteristics and solidification structures generated by computer-generated beam profiles, and how a steady-state simulation correlates with resulting part properties. Three beam profiles are evaluated, each designed for a specific melt pool geometry and temperature field. IN718 cube specimens are manufactured and analyzed by Archimedean density measurements and metallographic cross-sections. All profiles yield process windows with relative densities ≥ 99.0 % and build rates up to 16.8 mm3/s. The specimens exhibit a coarser solidification structure and waviness propagating through the part. Simulated melt pool depths correlate with measured densities, with 1.4-1.6 × layer thickness marking the onset of densification, while deviations between simulated and experimental melt pool geometries are observed.
Proceedings Inclusion? Planned: Post-meeting proceedings

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