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Updated: Jul 2, 2025

Additive Manufacturing of Functionally Graded Ceramic Materials by Stereolithography
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Improved Productivity with Multilaser Rotary Powder Bed Fusion Additive Manufacturing.

Peter Wang1, Gordon Robertson1, Brian T Gibson1

  • 1Manufacturing Science Division, Oak Ridge National Laboratory, Oak Ridge, Tennessee, USA.

3D Printing and Additive Manufacturing
|February 23, 2024
PubMed
Summary

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This summary is machine-generated.

Laser powder bed fusion (LPBF) can be scaled for mass production by using a novel architecture. This approach could increase production rates by four orders of magnitude, making it competitive with traditional manufacturing.

Area of Science:

  • Materials Science and Engineering
  • Additive Manufacturing
  • Mechanical Engineering

Background:

  • Laser powder bed fusion (LPBF) offers high geometric complexity and surface finish for various metals.
  • Current LPBF production rates (hundreds of grams/hour) are insufficient for mass production compared to traditional methods (kilograms to hundreds of kilograms/hour).

Purpose of the Study:

  • To explore scalable architectural concepts for Laser Powder Bed Fusion (LPBF) to achieve mass production rates.
  • To investigate methods for increasing LPBF deposition rates by up to four orders of magnitude.
  • To analyze the potential of optimized LPBF for manufacturing components like synchronous reluctance motors for electric vehicles.

Main Methods:

  • Conceptual exploration of a new LPBF architecture incorporating rotary table kinematics.
Keywords:
additive manufacturingmass productionrotary powder bed fusion

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  • Investigation of using a high density of simultaneously operating lasers with reduced optic sizes.
  • Analysis of improved scanning strategies and optimized toroidal build plate dimensions.
  • Productivity analysis applied to synchronous reluctance motors, considering printable soft magnetic alloys.

    • Main Results:

    • Proposed LPBF architecture has the potential to increase production rates by up to four orders of magnitude.
    • Specific design elements like rotary tables, multiple lasers, and optimized build plates are key to scalability.
    • Productivity analysis demonstrates feasibility for mass production of electric vehicle components.

    Conclusions:

    • A novel, scalable LPBF architecture is necessary for industrial mass production adoption.
    • The proposed concepts offer a pathway to significantly enhance LPBF throughput.
    • Optimized rotary powder bed fusion holds promise for the mass manufacturing of critical components in industries like electric vehicles.