Abstract Laser Powder Bed Fusion (LPBF) has emerged as a widely employed Additive Manufacturing (AM) technique, showcasing adaptability in processing a diverse range of materials such as metals, alloys, ceramics, and polymers. Its notable advantage lies in its capacity to handle intricate and cutting-edge designs, positioning it as the preferred choice for highly advanced applications within the AM domain. An emerging driver of LPBF advancement is laser beam shaping, which imparts significant benefits in controlling melt pool shape, characteristics, microstructure, and consequently influencing resulting mechanical performance. The ubiquitous use and widespread adoption of the Gaussian-shaped beam in both commercial and in-house developed LPBF printers is attributed to its substantial advantages and broad applicability across diverse materials. However, the intensity distribution of the Gaussian-shaped beam introduces challenges in LPBF, including issues such as un-melted powder spattering, high-temperature gradients, porosity formation, residual stress, and microstructure anisotropy. In response to these challenges, various alternative beam shaping profiles have been integrated into different LPBF printers, aiming to elevate printing quality and propel the advancement of the LPBF technique. This comprehensive review delves into a thorough examination and discussion of these alternative laser beam shaping profiles, considering their impact on melt pool shape, characteristics, and microstructure. Recognizing the pivotal role of LPBF simulation as a crucial tool for in-depth investigations which contributes to a deeper understanding of LPBF, this review paper additionally provides a mathematical formulation for these alternative shaping profiles, enabling their utilization in LPBF simulations.
Abdelmoula et al. (2026) studied this question.