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Oct 1, 2025

3D printing of metals: The Laser Powder Bed Fusion (LPBF)

The starting material is a metal powder, such as stainless steel, aluminum, or titanium. In an insulated chamber the metal powder is applied in thin layers of approx. 30 μm (0.03 mm) on a substrate plate. Based on the data of the CAD model, the laser moves over the powder layer and melts it according to the calculated areas, creating a homogeneous metal structure. The substrate plate is then lowered again to apply the next powder layer. The laser becomes active again and melts up precise areas of the metal powder according to the CAD data. In the process, the lower layers are bonded by laser melting. Layer by layer, the tailor-made product or a whole series of products is created.

The remaining powder is removed without residue at the end of the building process. Step-by-step laser melting allows several metal layers and their advantages to be combined. This is why the LPBF process is very advantageous, for example, in the development of highly efficient cooling structures. The selective Laser melted components have largely the same characteristics as the series material. In order to meet the highest dimensional and quality standards, the components can be reworked according to requirements. In contrast to classical milling or joining of single metal plates, the complexity and the level of detail does not increase the costs of production. The manufacturing costs are only determined by the material and volume used.

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