Powder Bed Fusion Laser Beam of Metal (PBF-LB/M) is a leading additive manufacturing technique known for producing complex metallic components with high precision. Despite its advantages, PBF-LB/M's broader application is often hindered by its slow build rates. Traditionally, increasing laser power to enhance build speed results in high peak intensities, causing evaporation of powder material and uncontrollable keyhole welding processes that produce defects such as spatters.


This presentation introduces a novel approach using beam shaping to manage and utilize increased laser power effectively. By implementing Multi-Plane Light Conversion (MPLC) technology, we can create various optimized beam shapes, such as annular or M-shaped beams, which significantly mitigate the challenges of high peak intensities. Notably, this flexibility allows seamless switching between beam shapes, adapting to different print scenarios while maintaining quality.


Utilizing both defocused Gaussian and ring-shaped laser intensity distributions, we achieved a notable 3.3-fold increase in printing speed for nickel alloy 625, without compromising the mechanical integrity of the components, as confirmed by rigorous testing. High-speed video and advanced particle tracing algorithms have further validated the efficacy of our beam shaping strategy under varied conditions, showcasing its potential to revolutionize LPBF applications. Mechanical properties of tensile bars printed with both defocused Gaussian and ring beam will also be presented.