Laser powder bed fusion (LPBF) is a type of additive manufacturing (AM) or 3D printing technology that uses a high-power laser to selectively fuse or melt layers of powdered material to build up a three-dimensional object. This process is particularly common in metal additive manufacturing, where it is sometimes referred to as selective laser melting (SLM) or direct metal laser sintering (DMLS).
Key features of laser powder bed fusion include:
Powder bed: The process begins with a thin layer of powdered material spread evenly over a build platform. Common materials include metals such as titanium, aluminum, stainless steel, and nickel alloys.
Laser melting: A high-energy laser beam is precisely directed onto the powder bed to selectively melt or sinter the powdered material according to the cross-sectional pattern of the desired layer. The heat generated by the laser fuses the particles, creating a solid layer.
Layer-by-layer building: After each layer is melted, a new layer of powder is spread over the previously solidified layer, and the process is repeated. This layer-by-layer approach continues until the entire 3D object is formed.
Cooling and solidification: Once a layer is melted, the molten material rapidly cools and solidifies, creating a bond with the previous layer. This helps ensure the structural integrity of the printed object.
Support structures: In some cases, especially for complex geometries, support structures may be added during printing to prevent deformations and ensure the stability of overhanging features.
Laser powder bed fusion is widely used in industries like aerospace, healthcare, and automotive for producing complex metal parts with high precision and specific material properties. Its ability to create intricate designs and functional prototypes makes it valuable for applications where traditional manufacturing methods might be impractical or costly.