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About this Abstract
Meeting 2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
Symposium 2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
Presentation Title Process Development and Thermal Monitoring in Electron Beam Additive Manufacturing of Tungsten
Author(s) Cristian Banuelos
On-Site Speaker (Planned) Cristian Banuelos
Abstract Scope Electron beam melting (EBM) presents significant challenges in the additive manufacturing of tungsten due to its high ductile-to-brittle transition temperature (DBTT) and susceptibility to cracking. This study aims to develop optimized processing parameters through real-time thermal monitoring using in-situ pyrometry during fabrication. Post-build characterization involves mechanical testing across temperatures spanning the DBTT, hardness measurements, and microstructural evaluation by microscopy to assess the effects of thermal history on material integrity. Particular attention is given to the influence of thermal gradients on defect formation and microstructural evolution during processing. Correlations between processing conditions, microstructure, and mechanical response are established to inform parameter development strategies. The objective is to enable the fabrication of dense, crack-free tungsten components suitable for high-performance applications, with an emphasis on advancing process understanding and thermal management strategies for refractory metals in additive manufacturing.
Proceedings Inclusion? Planned: Post-meeting proceedings

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Microstructure-Driven Fracture Behavior and Thermo-Mechanical Analysis of Large Area Additive Manufactured Short Fiber Composites
Microstructure and Mechanical Properties of Bulk EB-PBF Fabricated γ-TiAl: Post-HIP and Heat Treatment Effects
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MODAL: A Scalable Surrogate Modeling Framework for Scanwise Thermal Simulations in Laser Powder Bed Fusion
Modeling and Simulation of Cold Spray Additive Manufacturing: Insights Into Metallic Particle Bonding
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Numerical Modelling of the Interaction of a Laser Beam and Polymeric Powders During Polymer Laser Sintering
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Packing Fraction Sensing in Metal Binder Jetting Using Airborne Ultrasound Transducer
Photoelastic Visualization of Residual Stresses in PLA After Interlayer Shot Peening During Fused Filament Fabrication
Physics-Aware AI for Born-Qualified Additive Manufacturing: Toward Real-Time, In-Situ Part Qualification
Physics-Guided Thermal History Control to Improve Part Quality in Laser Powder Bed Fusion Additive Manufacturing
Polymer AM Part Thermal History From In-Situ Thermal Data and Heuristic Modeling
Pore Behavior in Melt Pool Properties Based on Ti-6Al-4V and SS316L Powders in Directed Energy Deposition (DED) Processes
Porosity Reduction in Large-Format Additive Manufacturing of Fiber-Reinforced Composites via Elongational Screw Design
Porous Membranes for Controlled Release Profiles using Stereolithography and Phase Separation
Post-Build CT Segmentation and Alignment with L-PBF In-Situ Monitoring Signatures
Powder Bed Interaction with Higher Translation Speed Electron Beams Path for the Area Printing
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Predicting LPBF Ti-6Al-4V Microstructure via Multi-Modal In-Situ Process Monitoring
Predicting Melt Pool Dimensions from Local Thermal Environment Through a Modified Rosenthal Solution
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Prediction of Failure in Additively Manufactured Metallic Components
Predictive Modeling of Particle Loading for Functional Grading in Reactive Extrusion Additive Manufacturing
Predictive Qualification of Laser Powder Bed Fusion: Leveraging Multi-Modal In-Situ Monitoring and Real-Time Control for Part Qualification
Printing Cryomilled Copper Chips by Blue Laser Directed Energy Deposition (DED)
Process-Aware Topology Optimization for Mitigating Residual Stress and Distortion in Laser Powder Bed Fusion
Process Development and Thermal Monitoring in Electron Beam Additive Manufacturing of Tungsten
Process Mapping for Single-Track Laser Wire Additive Manufacturing of AZ31 Magnesium Alloy
Producing Stochastic Metal Foam on Desktop FFF 3D Printers using Viscous Thread Printing
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Quantifying Machine-Induced Error in a Custom Binder Jet Platform for Radio Frequency Additive Manufacturing
Quantifying the Dynamic Properties of 3D Printed Polymers and Polymer Composites Via Ultrasonics
Radiative Property Characterization of Porous Medium Using Liquid-Based Advanced Micro-Additive Manufacturing Technique
Rapid and Non-Contact Density Measurement for Powder-Based AM Via Flash Thermography
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Real-Time Closed-Loop Control for Precision Liquid Metal Jetting
Real-Time Implementability Evaluation of FPGA-Based Trackwise Model Predictive Control for Laser Powder Bed Fusion
Real-Time Prediction of Working Distance in Laser-Wire DED Via Multi-Modal In-Situ Data Fusion Using a CNN Model
Real Time Measurement System for Digital Glass Shaping Processes
Real Time Visualization of Glass Additive Manufacturing Processes
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Reinforcement Learning-Based Digital Twin for Predictive Maintenance and Anomaly Detection in UR5 Robots
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Review on Atomization of Meals
Rheology-Driven Analysis of Extrusion Forces in Fused Filament Fabrication
Rheology-Informed Mixture Engineering of Aggregates for Extrusion Additive Manufacturing
Rheology Modification and Reinforcement of True Silicone Resins for Vat Photopolymerization
Robotic Subscale Bar-Fed Friction Stir Additive Manufacturing
Robotic Wire Arc DED (Directed Energy Deposition) of 316 l Stainless Steel Preform for Forging Application
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Sacrificial Preform Design and Parameter Optimization for Thin Walls and Corners in Powder-Blown Hybrid DED
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Selective Laser Etching of Fused Silica for Complex 3D Geometries
Sequential Element Rejection and Admission (SERA) Method for Topological Design of Cellular Materials
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The Influence of Hot Isostatic Pressing Process on the Fatigue Life of EB-PBF Printed Ti-6Al-4V
Thermal Exposure Optimization for Enhanced Interlayer Strength in FFF-Printed ABS: A DOE and Microstructural Investigation
Thermal History Prediction of More Complex Geometries for DED Based on SciML
Thermal Monitoring in AC Selective Laser Flash Sintering of Ceramics Using a Mid-Wave Infrared Photodiode
Toolpath Planning for Multi-Nozzle Concurrent Molten Metal Jetting Process
Top Layer Quality Assurance of Complex Geometries Based on Region of Interest in Additive Manufacturing
Topology and Orientation Optimized-Inspired Toolpath Planning for Continuous Fiber Material Extrusion
Toward Real-Time Finite Element Analysis-Informed Feedback Control of Wire-Arc Directed Energy Deposition via Robot Operating System 2 In-Situ Monitoring System
Towards Parametric Design for Additive Manufacturing of Coral Structures Using a Digital Twin Approach
Towards Scalable and Energy-Efficient Extrusion Additive Manufacturing of Thermoplastic Polymer Composites
Towards the Production of a 3D Part in Selective Laser Additive Manufacturing Acousto-Optic Light Engine (SLAM – ALE)
Train Small, Predict Big: Scalable Thermal Surrogate Modeling for LPBF Using MODAL
Transfer Learning for Process–Microstructure–Property Mapping in Micro Selective Laser Sintering
Transient Liquid Phase Surface Smoothing
Tribo-Mechanical and Corrosion Characteristics of SS316L-IN625 Alloys of Varying Compositions Fabricated by Twin Wire WAAM-TIG
Two-Component Thermoset Polymer Formwork for Concrete Casting
Uncovering Process-Structure Relationships in Directed Energy Deposition of Nickel-Based Alloys on Low-Alloy Steel with Post-Deposition Heat Treatment
Understanding Hardening Behavior Induced by Interlayer Shot Peening in Laser Powder Bed Fusion of 316L Stainless Steel
Understanding Multi-Line Printing and the Effects of Controlled Prewetting on Binder Jetting Print Cohesion
Understanding Sources of Spatial Density Variation in Green Parts Produced by Binder Jetting
Understanding the Effect of Heat Treatment on Mechanical Properties of Additive Manufactured 1.2709 Grade Maraging Steel
Understanding the Feasibility of Using NiTi55 Interlayer for Ti6Al4V-18Ni Maraging Steel Multi-Metal Deposition in L-PBF
Use of In-Situ Thermography to Study Scan Strategy for Laser Foil Printing of Metallic Glass
Using Acoustic Signals For Torch-to-Bead Distance Estimation and Closed-Loop Control in Wire Arc Additive Manufacturing
Using Coaxial Melt Pool Images to Construct In-Process 3D Volume Model in Powder Bed Fusion Additive Manufacturing
Using Machine Learning-Based Process Map to Guide Evaluation of Inconel 625 Mechanical Properties in Laser Foil Printing
Vat Photopolymerization of Na3V2(PO4)3-Based Electrodes for Sodium-Ion Batteries
Vat Photopolymerization of Ultra-Soft Polymer Foams
Volumetric Medical Models: Direct Imaging to Functional 3D Prints
Wire Arc Additive Manufacturing Benefits and Challenges: A Survey
Wire Arc Additive Manufacturing Development for Aluminum 6061 RAM
Wire Arc Additive Manufacturing of a Large Scale, High Aspect Ratio, Multi-Material Part
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