Powder Bed Fusion-Laser Beam (PBF-LB/M) offers remarkable opportunities for the fabrication of Functionally Graded Materials (FGMs), enabling spatially variable properties within a single component. This work presents an innovative strategy for the production of intralayer FGMs using a novel and cost-effective powder separation system that can be retrofitted to conventional PBF-LB/M machines equipped with blade or roller spreading mechanisms. Two deposition strategies were investigated: (i) a pre-deposition blending approach involving pre-mixing of feedstock powders prior to deposition and (ii) an inline mixing method involving real-time mixing during the deposition process using a custom-designed interface divider. The feasibility of this dual approach was demonstrated using CoCrMo and AISI 316L powders, selected for their complementary properties such as mechanical robustness, biocompatibility and corrosion resistance - properties of critical importance for both biomedical implants and aerospace components. Layer-by-layer fabrication allowed a local transition in material composition across the plane of each layer, which differed significantly from the traditional z-direction gradation. Microstructural and chemical analyses confirmed well-defined interfaces with strong metallurgical bonding. Mechanical tests showed a promising gradual transition in properties, with overall results very encouraging. This approach bypasses the complexity and cost associated with custom multi-material printing systems and provides a scalable and industrially viable solution for the production of metallic FGMs. By seamlessly integrating with standard AM platforms and avoiding significant hardware modifications, the proposed system opens new avenues for resource-efficient, sustainable multi-material manufacturing in high-performance sectors.

We acknowledge financial support under the National Recovery and Resilience Plan (NRRP), Mission 4, Component 2, Investment 1.1, Call for tender No. 1409 published on 14.09.2022 by the Italian Ministry of University and Research (MUR), funded by the European Union – NextGenerationEU – Project Title OPTIMA - Optimization of Performances of The Innovative Multi-material Metallic Parts Obtained by Additive Manufacturing – CUP D53D23018130001 - Grant Assignment Decree No. 1385 adopted on 01.09.2023 by the Italian Ministry of Ministry  of University and Research (MUR).