The Laser Powder Bed Fusion (LPBF) process developed by Fraunhofer ILT celebrated its 25th anniversary in November 2021, providing an opportunity to look back and look ahead at this special technology.
Today, LPBF is widely used in industry in areas such as turbomachinery and automotive engineering, aerospace and medical technology. The metal powder is applied layer by layer using a doctor blade. In each of these work steps, the laser beam is moved along calculated paths over the powder bed. By melting the metal powder, the workpiece is produced layer by layer in the intended shape.
The production costs depend less on the complexity of the geometry and more on the volume of the component. The layer-by-layer build-up process makes it possible to reduce three-dimensional manufacturing tasks to two dimensions and to produce complex functional parts in a resource-efficient and economical manner. As a result, the process offers a number of systematic advantages compared to conventional manufacturing techniques such as primary forming or machining.
For example, complex cooling channels for the targeted temperature control of tools or integrated grid structures for lightweight applications are possible. Prototypes in small batches can also be produced in the shortest possible time, thus reducing development times.
