Feedback loop controls are being integrated into Laser Powder Bed Fusion (LPBF) systems to mitigate costly build failures and ensure first-time right prints. Integrating a feedback loop control with unique laser configurations allows for tighter thermal input by manipulating the process variables. However, the ability to change parameters during a print makes part qualification difficult. Further, unique laser configurations such as Leader-Follower mode complicate qualification by introducing more variability to the printing process.

This experimental study investigates the material response from controlling different laser configurations. The Ohio State University’s Center for Design and Manufacturing Excellence (CDME) worked with R3-Digital Sciences to integrate R3-DS’ Artisan-AM™ feedback loop control software on an OPEN ADDITIVE Panda system. This system is equipped with 2 lasers (nLight AFX and Coherent ARM) with full field overlap allowing for continuous leader-follower processing. Together the team established key parameter ranges for Artisan-AM™ to modify in-situ. To evaluate the material response, 3 builds were conducted: A single laser build, A pre-heating with melting laser build, and a melting laser with post-heating build. The outcome of this study is an understanding of dual leader-follower improvements over utilization of a single laser. Results include the feasibility of integrating a commercial feedback loop to the LPBF process, up and downskin deviation response, density analysis, and an evaluation of potential acicular α’ propagation in Ti-64.