Over the past decade, metal additive manufacturing, specifically laser powder bed fusion (LPBF), has emerged as a prominent approach for producing advanced end-use components. Despite its advantages, LPBF is currently constrained by relatively slow deposition rates and a limited range of processable materials. These limitations are driven in part by the high peak intensities associated with conventional Gaussian laser beam profiles, which restrict laser power and scan speed, can generate excessive spatter, and provide almost no control of material cooling rate.

To address these challenges, beam shaping technology has received significant attention as a means of improving LPBF process performance. Compared to traditional Gaussian profiles, beam shaping lasers enable a more uniform distribution of energy within the melt pool, facilitating increased throughput, improved printability of hard-to-process alloys, reduced spatter generation, and enhanced control over microstructure evolution.

The University of Dayton Research Institute (UDRI) designs and develops LPBF research platforms to support the rapid integration of emerging laser technologies, in-situ sensing methodologies, and advanced materials research. As part of this effort, UDRI has incorporated multiple beam shaping technologies into its DART (Dayton Additive Research Technologies) systems, including next generation laser sources and dynamic focus optics.

Discussion will include the integration of beam shaping technologies into LPBF systems, laser beam characterization, and initial experimental findings.