Development of a build volume reduction kit for studying epitaxial re-solidification in laser powder bed fusion

Abstract Laser powder bed fusion (PBF-LB/M) is a promising additive manufacturing process that enables the production of complex and high-performance parts. However, the high cost of materials and the need for large quantities of powder in conventional industrial-grade systems pose challenges for experimental materials development and testing activities. This study focuses on the development of a modular build volume reduction kit for an existing EOS EOSINT M-series PBF-LB/M machine. The proposed build volume reduction kit can be customized and adapted for specific research needs, expanding the capabilities of existing infrastructure without significant capital investment. This study describes the design and characterization of the build volume reduction kit and a detachable Pt-heater module, which allows for preheating of the substrate material above 500 °C. The kit’s operation was validated by manufacturing simple cuboid samples using EOS 316L stainless steel powder on a 316L stainless steel substrate. The results demonstrate the feasibility of using the reduction kit for cost-effective experimental investigations, as well as highlighting its potential for studying the epitaxial solidification of PBF-LB/M-built functional materials.