Breakthrough Research Improves 3D Printing for Metals

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Production rate increased sixfold, 50 percent lower costs, significantly reduced energy consumption and material waste, and even better component quality—this is the outcome of the research results from the EU project "InShaPe."

Although powder bed-based additive manufacturing of metals is now established for producing complex metal components, rigid laser beam profiles and insufficient process monitoring methods often cause problems during the melting process. This can lead to material defects and production stoppages, resulting in scrap, increased energy consumption, and higher production costs. However, the specialists involved in the "InShaPe" project have developed a new approach to process optimization over the past three years, combining AI-driven laser beam shaping with multispectral imaging (MSI) for powder bed fusion of metals (PBF-LB/M). The goal of the project was to significantly improve the efficiency, cost-effectiveness, and sustainability of this additive manufacturing process, which appears to have been achieved and demonstrated with five challenging examples from aerospace, the energy sector, and mechanical engineering.

AI Beam Shaping and Multispectral Imaging

The project partners succeeded in significantly increasing the productivity of the PBF-LB/M process. For various industrial applications, productivity increases of over 600 percent (6.2 times more than usual) were achieved, including production rates of up to 93.3 cubic centimeters (approx. 5.7 fl oz) per hour (for Inconel-718 components), while cutting manufacturing costs in half. To demonstrate the success, an impeller for aerospace (Inconel 718), an industrial gas turbine component (Inconel 718), a part of a spacecraft combustion chamber (CuCrNb), a chainsaw engine cylinder head (AlSi10Mg), and satellite antenna components were produced. The "intelligent" beam shaping combined with multispectral imaging worked closely together to significantly improve the additive manufacturing process. The laser beam profile is tailored to the specific component, taking geometry and material into account. This enhances component quality and enables faster processing by reducing defects like cracks, splatter, and condensate formation, which would otherwise lead to rework or scrap. A ring-shaped beam profile in combination with optimized scanning strategies proved particularly advantageous for a variety of applications. The laser energy is applied through a ring-shaped intensity distribution to create the melt pool, optimizing the printing process, as the report indicates.

No More Annoying Interruptions During 3D Printing

Simultaneously, the new multispectral imaging captures signals across various wavelength ranges and monitors the PBF-LB/M process in real time. This enables early detection of thermal changes in the melt pool. The collected data is directly integrated into process control. Errors that previously led to production interruptions or rework can now be corrected, allowing the process to continue without significant delays. Overall, this innovative approach represents an important advancement toward industrial-scale production with PBF-LB/M. The interplay between beam shaping and MSI-based process control results in a more stable melting process, reduces sources of errors, and enables a more targeted and resource-efficient use of energy. Ultimately, complex metal components can be produced faster, cheaper, and more sustainably, without compromising on quality.

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