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Meeting 2024 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2024)
Symposium 2024 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2024)
Presentation Title Laser Beam Sources and their Influence on Tailored Microstructure, Mechanical Properties, and Increased Productivity in Laser Powder Bed Fusion Additive Manufacturing
Author(s) Cesar A. Terrazas
On-Site Speaker (Planned) Cesar A. Terrazas
Abstract Scope Recent advances in laser powder bed fusion (L-PBF) additive manufacturing of metals involve the use of lasers with tuneable intensity profiles enabling the control of the energy distribution and hence of the thermal gradients and the solidification pathway during the material deposition process. In this work, we present current developments involving the use of various laser sources applied in a L-PBF platform from Aconity3D GmbH. Several case studies will be presented to showcase tailoring microstructural features and mechanical performances of components built using both traditional laser sources with a Gaussian intensity distribution and those in which the emission profile is controlled (i.e. ring beam or top hat) at discretion while shifting the productivity to the next level. Results are presented for several materials of interest in the fields of aerospace, automotive and medical, and to the larger additive manufacturing community.
Proceedings Inclusion? Definite: Post-meeting proceedings

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Enhancing Standards Education in Additive Manufacturing and Robotics: A Systematic Approach and Curriculum Integration
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Establishing a Pipeline for the Scanning, Editing, and Full-color Additive Manufacturing of Cadavers for Anatomy Training
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Exploring the Impact of Pre- and Post-heating on Residual Stresses in Laser-directed Energy Deposition: A Numerical Investigation
Exploring the Influence of Geometrical Features on Mechanical Property Variation in LPBF Parts Through Simulation
Exploring Toolpath Strategies in Wire-arc Directed Energy Deposition for Enhanced Material Properties in Inconel 625
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High-Speed Imaging Investigation and Process Mapping of the Plume Behavior in Laser Powder Bed Fusion
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High Precision In-Situ Alignment Procedure in Dual Laser Powder Bed Fusion for Congruent Laser Operation
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High Temperature 3D Printing of Polyamide Magnetic Composites
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Highly Productive Multi-Material Laser Wire DED
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Improving the Design for Additive Manufacturing Process with Design of Experiments to Characterize Geometry-Dependent Porosity and Surface Roughness
Improving the Mechanical Properties of Fused Deposition Modeling (FDM) 3D Printed Polypropylene/ Carbon Fiber Parts
In-Situ Laser Powder Bed Fusion: Real-Time Assessment of Residual Stress through Thermal Gradient Analysis
In-Situ Layer-Wise Generation of 3D Thermal Point Clouds for AM via Embedded 3D Scanning and Thermal Data Fusion
In-Situ Layer Temperature Monitoring Enabled by Machine Vision
In-Situ Melt Pool Monitoring to Optimize Laser Powder Bed Fusion of Scalmalloy®
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In-Situ Powder Assessment by Frequency-Domain Thermal Response
In-Situ Powder Assessment by Frequency-Domain Thermal Response
In-Situ Print Layer Height Correction Framework for Wire Arc Additive Manufacturing
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In-Situ Ultra-Fast Laser Processing in LPBF for Surface Quality Improvement and Defect Removal
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Influence of Novel Space Filling PBF-LB Scanning Strategies on Part Distortion and Density
Influence of Powder Particle Size Distributions on Surface Topography of Polymer Laser Powder Bed Fusion Parts
Influence of Scanning Strategy on the Microstructure and the Mechanical Properties of AlSi10Mg Parts Fabricated via LPBF
Influence of Testing Method on Fatigue Performance of PBF-LB 316L Stainless Steel with As-Built Surfaces
Influencing Residual Stress in PBF-LB/M Processes through In-Process Microstructure Assessment and Selective Laser Heat Treatment
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Innovative Approaches to Fabricate Terahertz Optics with Additive Manufacturing: Manufacture and THz Characterisation of a Silica-Filled Photopolymer
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Integrating Automated Assembly and 3D Printing for the Manufacture of Miniature Pipe Inspection Robots
Integrating In-Situ Sensing for Adaptive Control of Powder Deposition to Advance Remanufacturing Processes
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Investigating the Effect of Workpiece Shape on Thermal History and Coating Properties in High-Speed Coatings Using Laser Directed Energy Deposition
Investigating the Impact of Decontamination on Recycled Polymer Viability in Additive Manufacturing
Investigation of Process Parameters to Fabricate TiWMo Refractory Medium Entropy Alloy via Selective Laser Melting on Different Substrate Materials
Investigation of the Effective Anisotropy for the Triply Periodic Minimal Surface Lattice under Varying Applied Stress Orientation
Iterative Learning for Efficient Additive Mass Production
Large-Scale, Conveyor Belt-Assisted Robotic Additive Manufacturing: System Design and Toolpath Planning
Laser-Powder Bed Fusion Processing Effects on Microstructural Texture in Nickel Superalloy
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Laser Induced Breakdown Spectroscopy for Chemistry and Composition Monitoring of Laser Powder Bed Fusion Processing
Laser Powder Bed Fusion Copper: Post-Processing, Structure, Property Relationships
Laser Powder Bed Fusion of High-Strength Aluminum Matrix Composites
Laser Powder Bed Fusion of Nickel Aluminum Bronze in Nitrogen Environment
Laser Powder Bed Fusion Process Feedback Control based on In-Situ Powder Layer Thickness
Laser Speckle Photometry for Residual Stress Diagnosis of Laser Powder Bed Fusion Processing
Laser Tempering for Hybrid Additive Manufacturing
Lights-Out Hybrid Additive-Subtractive Manufacturing of Ti-6Al-4V Using Laser Powder Bed Fusion
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Local Porosity Detection in LPBF Manufactured Aluminum Parts by In-Situ Multi-Sensor Monitoring
Location-Specific Engineered Microstructure Using Interpenetrating Lattices in Laser Powder-Bed Fusion
Low-Cost Calibration Plate for Enhanced In-Situ Monitoring in Laser-Powder Bed Fusion (L-PBF)
Low-Cost Melt Pool Monitoring in Wire Arc Additive Manufacturing
Machine-Learning Assisted Prediction of Surface Roughness in Powder Bed Fusion Process with Inconel Super Alloy
Machine Design and Process Development of Volumetric Polymer Powder Bed Fusion by Radio Frequency Additive Manufacturing (RFAM)
Machining PBF-L SMAs to Improve Geometrical Accuracy and Surface Quality
Magnetic Properties of Binder-Jetted Soft Magnetic Toroidal Inductor
Manuscript Test Abstract
Material Extrusion Additive Manufacturing Molds for Thermoset Composites
Measurement and Control in Digital Glass Forming (DGF)
Measurement Apparatus for Determining the Reflected, Absorbed, and Transmitted Energy during a Low Strain Rate Impact Event
Measuring Temperature during AC Selective Laser Flash Sintering
Measuring Thermomechanical Response of Large-Format Printed Polymer Composite Structures via Digital Image Correlation
Mechanical and corrosion properties of stainless steel fabricated by wire arc additive manufacturing (WAAM) using weave and stringer beads
Mechanical Performance of Lattice Structures Fabricated via Burst-Mode Drop-on-Demand Molten Metal Jetting (DoD MMJ)
Melt Pool Depth Contour Prediction from Surface Thermal Images with Transformer Models
Melt Pool Temperature Measurement Across Multiple Metal AM Processes through Application of Two-Color Thermal Imaging
Melt Track Formation Process with a Constant Linear Energy Density in Laser Powder Bed Fusion Revealed by In-situ X-Ray Imaging and Temperature Measurement
Microstructural and Mechanical Heterogeneity Observed in Additive Friction Stir Deposition Ti-6Al-4V
Microstructure-Informed Thermal-Mechanical Simulation of Multi-Bead Structures for Large Area Additive Manufacturing Polymer Composite Extrusion/Deposition
Microstructure and Crack Propagation in IN718 Samples Fabricated by Laser Powder-Bed Fusion
Microstructure Prediction in Laser Powder Bed Fusion using Heterogeneous Sensing, Process Modeling, and Machine Learning
Minimizing Drying Defects for Large-Scale Parts Fabricated by Ceramic On-Demand Extrusion
Minimizing Large Distortions in Binder Jetted Parts via Accurate Modeling and Compensation
Mitigating Distortion Challenges in Additively Manufactured Metallic Parts
Mitigating Overspray in Aerosol Jet Printing: A Deep Learning Approach for Process Optimization
Mixed Polymer Blend Composites Reinforced with Graphene Oxide for 3D Printing
Model-Based Production Operational Control for Metal Additive Manufacturing
Model Based Control of Fused Powder 3D Printing
Modeling of Laser Stirring Scan Strategy in LPBF for High-Throughput Applications
Modeling the Effect of Thermal Contact Resistance on Mechanical Properties in Fused Filament Fabrication
Mold Design using Binder-Jetted Sand for Aluminum Casting
Molten Metal Jetting for Repairing Aluminum Components
Molten Metal Jetting of Copper and Silver Electronic Traces
Molten Metal Jetting (MMJ) A356 and 6061 Heat Treatment, Tensile Properties, and Fracture
Monolithic Glass Forming using Laser Heated Sculpting
More Efficient Lattice Testing using an Optimal Design of Experiments Approach
Multi-Axis Routing of Syringe Deposited Conductive Traces over Topology-Optimized Multi-functional Structures
Multi-Axis Wire-Arc Directed Energy Deposition of a Topology Optimized Aircraft Component
Multi-Laser Powder Bed Fusion of Cu10Sn Using Low-Power 450nm Diode Lasers
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Numerical and Experimental Advances In Piston-Actuated Molten Metal Droplet Jetting
Numerical Simulations and Experimental Validation of Laser-Foil-Printing Additive Manufacturing
Numerical Simulations of Melt Pool Physics in Laser Powder Bed Fusion Processes
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On the Nature of Recoater Damage Powder Spreading Mechanics
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Ontology-based Retrieval Augmented Generation (RAG) for GenAI-Supported Additive Manufacturing
Optical Expansion of Projection-based 3D Printing
Optical Tomography based on Near Infrared Imaging for Spatter and Distortion Detection in LPBF
Optimal Silane Concentration for Strengthening PA12 and SFO Composite Filaments in FDM Printing: Preliminary Insights
Optimization of SiC Colloidal Ink for Direct-Write Additive Manufacturing via Dual-Polyelectrolyte Ratio Method
Optimizing Molten Metal Deposition (MMD) for Aluminum Alloys: A Synergetic Approach of Finite Element and Experimental Study
Overcoming the Resolution-Deposition Limit of Additive Manufacturing with Droplet-on-Demand Molten Metal Jetting
Overview of Key Technoeconomic Performance Metrics for Large-Format Directed Energy Deposition Metal Additive Manufacturing
Parametric Investigation of Single-Layer Stainless Steel 316L with Novel Laser Powder Bed Fusion Technology: Diode Area Melting with 450 nm Blue Lasers
Part-Level Heat Buildup Across Directed Energy Deposition Additive Manufacturing Processes
Part Deformation Constrained Multi-load Support Optimization for Laser Powder Bed Fusion
Passive Intensity Modulation Of Light In A Microscale Selective Laser Sintering System For Enhanced Part Uniformity
Performance Analysis of Selective Separation Shaping (SSS) Large-Scale Powder Bonding Technology
Phase-field Simulations of Solute Element Segregations at Various Interfaces in Additively Manufactured IN718 Ni-based Superalloy
Photocurable SLA Resin Formulation for Reduced Thermal Expansion
Physics-based Machine Learning for In-Situ Infrared Detection of Micropores in LPBF
Physics-based Modeling of Polymer-Metal Composites in Fused Filament Fabrication
PLA-HA/BBG Composite Scaffolds Fabricated by Digital Light Processing 3D Printing for Cranial Bone RegenerationRegeneration
Planar and Non-planar Print Patterns in PEEK Flat Backup Rings to Increase Seal Performance Under High Pressure and Temperature
Powder Feed Mechanism for Convection of High-Cohesion, Sub-20-Micron Powders in Directed Energy Deposition
Powder Packing and Part Removal in Compressed Powder Beds
PowderJet: An Agile System for High Quality Metal Powder Production
Pre-training Vision Encoders with Thermal Images for In-situ Process Monitoring in Laser Powder Bed Fusion
Predictability of Drag force Towards Optimizing Fingers to Aid Automation in the Depowdering Stage of Binder Jet AM & Granular Physics
Predicting Melt Pool Thermal Distribution in Ti-6Al-4V Directed Energy Deposition Using Machine Learning
Predicting Microstructure Properties Using Transfer Learning
Predicting Print Morphology in Aerosol Jet Printing Using Deep Learning-based cGANs
Predicting Recoater Interference in Laser Powder Bed Fusion Process by Considering Both Global Thermal Deformation and Local Edge Deformation
Predicting Surface Roughness in Laser Powder Bed Fusion Parts after Laser Polishing: A Multi-Physics Simulation Approach
Predicting the Fatigue Life of a Multi-Jet Fusion Fabricated Polyamide 11 Ankle-foot Orthosis: Durability Insights from S-N Curve Analysis
Prediction of Fatigue Properties of Fiber-reinforced Composites Manufactured by Material Extrusion
Predictive Modeling of Clay Drying Process in Ceramic 3D Printing
Prewetting of Binder Jet Print Beds to Improve Line Quality and Expand Print Windows
Probing the Effect of Dislocation Cell on the Plasticity and Anisotropy of Additively Manufactured Copper via Crystal Plasticity Finite Element Modeling
Probing the Process Window Boundaries in Powder Bed Fusion-Laser Beam of Ti-6Al-4V
Process Development and Control for Sensor-informed Hybrid-Additive Manufacturing
Process Limitation for Powder Bed Fusion with Laser Beam Multiplication
Process Optimization of Diode Point Melting Using Ti6Al4V in Laser Powder Bed Fusion
Process Parameter Development for SS316L on the Freemelt-ONE Open Architecture Electron Beam Powder Bed Fusion Machine
Process Parameter Effects on the Mechanical Behavior and Microstructure of Fused Filament Fabricated 17-4 PH
Process Planning Toolbox for Cold Spray Additive Manufacturing Iterative Build Plan Optimization
Processing Aluminum Alloys with Piezoelectric Driven Molten Metal Jetting
Processing of Recycled PEKK-CF in Powder Bed Fusion
Proposal for How to Treat L-PBF Like Any Other Plant: State Feedback Control Design and Computational Issues
Pros and Cons of Industrial Robotics in Additive Manufacturing
Prospects of Fusion Additively Manufactured Microstructures for Enhancing Hydrogen Embrittlement Resistance
Quantification of Recoating Forces in Binder Jetting
Quantitative Analysis of In-situ Pore Removal in Porous L-PBF Substrates
Rapid 3D Printing of Electro-Active Hydrogels
Rapid Curing of Ceramic Binder Mixtures Using Microwave Radiation
Rapid Screening of Liquid Metal Wetting for a Materials Compatibility Library
Re-Defining Catheter Care with Multi-Material Additive Manufacturing
Re-Imagining Additive Manufacturing through Multi-Material Laser Powder Bed Fusion
Real-Time Process Visualization in Thermoplastic Extrusion with Augmented Reality Monitoring
Reconfigurable Lattice of Auxetic Backlash Structures for Shape-Changing Surfaces
Reduction of Aging Mechanisms in a Polyamide 66 Material for Use in the Laser-based Powder Bed Fusion Process
Region of Interest Analysis for Top Layer Quality Control in Thermoplastic Extrusion in Additive Manufacturing
Reinforcement Learning for Energy-Efficient Toolpath Generation in Additive Manufacturing
Research on Influence of Scan Strategy on Part Shrinkage in Low Temperature Laser Sintering of Polymer
Residual Stress Evaluation of EB-PBF Produced High Strength Mo-7Re-1HfC Alloy via Neutron Diffraction
Robotic Convergent Manufacturing of Large Format Structures
Shape Memory Alloy Enabled Interlocking Metasurfaces by L-PBF
Simulation and Estimation of Mechanical Properties of Additively Manufactured Metal Components
Size and Shape Optimisation for High-Performance Battery Electrodes
Size Effect on Porosity of Thin Struts Fabricated by Laser Powder-Bed Fusion (L-PBF)
Smooth 3D Transition Cell Generation based on Latent Space Arithmetic
Sol-Gel Synthesis Integrated 3D Printing of Lithium Nickel Cobalt Manganese Oxide
Solar Harvesting and Photothermal Energy Generation via Multiple Transparent Plasmonic Fe3O4@Cu2-xS Thin Films
Soldering and Electroplating to AM Surfaces
Spreadability of Raw Sand in Binder Jet Additive Manufacturing: Examining Feasibility Using Numerical Methods
Statistical Process Control for WAAM for Productivity and Quality Improvements
STEAM Powered: An Argument for the Robust Integration of Artistic and Engineering Practices in Design for Additive Manufacturing
Stop Building Naked Lattices! A (More Than) Modest Mechanical Property Improvement Strategy
Strategizing Scan Technique Selection for Component Remanufacturing Using 3D Printing: A Combined Reverse Engineering and TOPSIS Based Multi Criteria Decision Making Framework
Study of Additively Manufactured Tungsten and Tungsten alloys via Laser Based - Directed Energy Deposition Process for High Temperature Applications
Study of Using a Secondary Pulsed Laser for Process Control in Laser Powder Bed Fusion
Surface Roughness Measurements of Additively Manufactured Components via X-Ray Computed Tomography
Surface Roughness of the Micro Milled 3D Printed 316L Stainless Steel Parts Fabricated by FDM/ FFF Technology
Sustainable Waste Management In Additive Manufacturing: Old And New Strategies To Divert Industrial Waste From Landfills
Symmetric Build Plate Deposition: A Strategy to Mitigate Solidification-Induced Residual Stresses in DED-Arc Additive Manufacturing
Synchrotron-based In Situ/Operando Characterization Capabilities at NSLS-II
Synergizing Machine Learning and Multiphysics Simulation for Spatter Process Map Generation in LPBF Processes
Temperature Control of Digital Glass Forming Processes
Tensile and Fatigue Analysis of Functionally Graded Materials with Varying Concentrations Manufactured Using Material Extrusion
The Behaviour of First-Generation Bio-Composites in a Multi-Axis Material Extrusion Application
The Development of a Precise Quick Response Apparatus for Functional Grading in Reactive Extrusion Additive Manufacturing
The Effects of Laser Absorption and Shielding in Plasma Vapor Jets Induced by Continuous Wave Laser Irradiation of Tungsten
The Effects of Multi-laser Process Parameters in LPBF Manufactured Inconel 718
The Impact of Different HIP Treatment Cycles on Fatigue Behavior during 4-Point Bending of Additively Manufactured (AM) Ti-6Al-4V
The Influence of Contour Offset in Laser Powder Bed Fusion
Thermal-Assisted Direct Ink Write 3D Printing of Stainless Steel 316L Colloidal Pastes
Thermal and Mechanical Characterization of Lightweight PLA Filaments for Material Extrusion
Thermal Emission-Based Geometric Mapping of Specular Glass Surfaces
Thermographic Porosity Estimation by Monitoring Non-Uniformity of Intra-Layer Cooling During Hybrid Directed Energy Deposition
Titanium Wire Arc Additive Manufacturing Inert Enclosure and Material Handling Safety Considerations
Toolpath Planning for Additively Manufactured Continuous-Fiber Reinforced Composties Designed by Topology Optimization
Topology-Driven Information Embedding in Structural Components
Topology Optimisation of Bespoke Lattice Orthopaedic Implants
Topology Optimised Multi-Material MBB Beam Fabricated via Powder Bed Fusion
Toward In-Situ Sensing of Powder Packing Density In metal Binder Jetting Using Recoating Force
Toward Parametric Heat Transfer Solvers in Additive Manufacturing
Toward Rapid Process Qualification of Laser Powder Bed Fusion Additive Manufacturing Using Physics-Based Model Predictive Control
Toward Real-Time Adaptive Material Control in Large-Scale Robotic Additive Manufacturing
Toward SmartScan 2.0 - An Intelligent Scanning Sequence Optimization Method for Reduced Part Deformation and Residual Stress in LPBF Based on Thermo-Mechanical Models
Towards Affordable Aluminum Additive Manufacturing: Considerations on the Manufacturing of Non-Explosible NExp-1 AlSi10Mg on Medium-Wattage Systems
Towards an Analytical Model for Multi-Objective Optimization of Cellular Materials
Towards Experimentally-Informed Modeling of Conduction for Improved Finite Element Thermal Prediction of Wire-Arc Directed Energy Deposition
Towards Freeform Additive Manufacturing: Recent Improvements Made on ORNL Large Scale Metal Slicer to Meet the Challenges brought by Growing Complexity of Parts in Wire-arc Additive Manufacturing
Towards High Resolution and High Speed Metal AM with Molten Metal Droplet Jetting
Towards Sustainable Fabrication of Electronics via Molten Metal Jetting
Towards Sustainable Rechargeable Batteries via Single Point Exposure Laser Powder Bed Fusion of Pure Zn Lattice Structures
Towards the Feasibility Analysis and Additive Manufacturing of a Novel Flexible Pedicle Screw for Spinal Fixation Procedures
Ultrasonic Vibration Augmented Fused Deposition Modeling through Step-wise Contour Scanning
Understanding Melt Pool Variation Due to Geometric Features and Scan Pathing
Understanding Melt Pool Variation Due to Geometric Features and Scan Pathing
Understanding Microstructure and Oxide Distribution in ODS Steels through Thermodynamic Simulations and Melt Pool Analysis in LPBF Processes
Understanding the Impact of Printing Strategies on Drop-on-Demand Molten Metal Jetting Technologies
Universal Differential Equations for Transient Thermal Modeling of Directed Energy Deposition Additive Manufacturing
Unsupervised Multi-Modal Machine Learning for In-Process Monitoring of Additive Manufacturing
Unveiling Gas–Liquid Metal Reactions in Metal Additive Manufacturing: High-Fidelity Modeling Validated with Experiments
Unveiling Spot Melting Strategies for Microstructure Control in Electron Beam Powder Bed Fusion
Upcycling Machining Chips for Additive Friction Stir Deposition Feedstock Production
Use of an Acousto-Optic Deflector Light Engine to Improve Resolution and Speed of the Stereolithography Process
Use of Cored Wire in the Optimisation of New Alloys for Laser Powder Bed Fusion with Tailored Mechanical and Corrosion Properties
Using Laser Ultrasonics to Measure Localized Changes in Young’s Modulus caused by Select Laser Flash Sintering
Using Trilinear Coordinate Measurements to Inform Prior Models for Minimally-Invasive Material Extrusion Path Planning
Variations Across Length Scales in Additively Manufactured Ti- 6Al-4V Parts: Challenges to Repeatability and Reproducibility
Vector-Level Feedforward Control of LPBF Melt Pool Area Using a Physics-based Thermal Model
Wire Arc Additive Manufacturing of Multi-material Parts Using H-13 Tool Steel
Wire Feed Speed Based Layer Height Controller for Wire Arc Additive Manufacturing
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