Increase of theoretical build rate in laser powder bed fusion through adapted laser intensity distribution

Laser powder bed fusion (L-PBF) is an advanced manufacturing process with slow build rates. Increasing laser power using conventional Gaussian beams leads to high peak intensities, causing material defects. Solutions include defocusing the laser beam within the Rayleigh length and using beam-shaping technologies like Multi-Plane Light Conversion (MPLC). MPLC can switch beam shapes, enhancing printing speeds and quality. This method achieved a 3.3-fold speed increase for nickel alloy 625, with improved mechanical performance confirmed by tests.