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This is a Experimental Study study.

October 1, 2025

Laser Powder Bed Fusion Process Feedback Control Based on In-Situ Powder Layer Thickness

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In-situ measurement of powder layer thickness improves process reliability in laser powder bed fusion, suggesting enhanced quality control.

The actual layer thickness stabilizes around 100 μm, exceeding the programmed 40 μm thickness, impacting quality.
Experimental analysis over 118 layers reveals significant volume shrinkage after laser exposure, measuring approximately 60 μm.
Identified recoater-induced defects, including scratches and waviness, contribute to inconsistencies in manufactured parts.
Integrating real-time feedback control may enhance future optimization efforts for improving LPBF processes.

Neira et al. (2025) studied this question.

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In-situ measurement of powder layer thickness improves process reliability in laser powder bed fusion, suggesting enhanced quality control.