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Recent Advances and Applications of Laser-Based Additive Manufacturing

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Additive Manufacturing Technologies".

Deadline for manuscript submissions: closed (20 February 2026) | Viewed by 5666

Special Issue Editors


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Guest Editor
School of Engineering, Liverpool John Moores University, Liverpool L3 5AH, UK
Interests: corrosion; electrochemistry; additive manufacturing; laser processing; tribocorrosion; tribology
Special Issues, Collections and Topics in MDPI journals

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Guest Editor
School of Engineering, Liverpool John Moores University, Liverpool L3 5AH, UK
Interests: machining; additive manufacturing; digital manufacturing; process and condition monitoring
Special Issues, Collections and Topics in MDPI journals

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Guest Editor
School of Engineering, Liverpool John Moores University, Liverpool L3 5AH, UK
Interests: laser materials processing with particular interests in laser texturing and other surface treatments; processing of carbon fibre reinforced polymers; additive manufacturing; laser hardening; cutting and drilling; growing interest in digital twinning of laser processes

Special Issue Information

Dear Colleagues,

Laser additive manufacturing is one of the most popular new technologies in the manufacturing field. This is because it permits the generation of metallic complex structures, as well as the creation of new alloys and super isotropic alloys with new properties.

The possibility of designing metallic structures and properties has caught the attention of several industrial sectors such as biomedicine, construction, power, automotive, aerospace, and microelectronics. Various methods to carry out laser additive manufacturing currently exist, each with their own advantages and disadvantages. All methods, however, possess high reproducibility, automatization, precision, and environmental friendliness. New laser additive manufacturing methods are also in development.

This Special Issue will focus on specimens fabricated with laser additive manufacturing methods.

Subjects of interest include new laser additive manufacturing methods, the production of new alloys, and structure fabrication with traditional methods. Additionally, the evaluation and assessment of the chemical, physical, and mechanical properties of these new samples will be covered by this Special issue.

Dr. Juan Ignacio Ahuir-Torres
Dr. Tahsin Öpöz
Dr. Martin Sharp
Guest Editors

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Keywords

  • powder bed fusion
  • selective laser sintering
  • selective laser melting
  • direct energy deposition
  • spatial light modulator
  • material jetting
  • stereolithography
  • super isotropic alloys
  • mechanical properties
  • biomaterial
  • corrosion

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Published Papers (2 papers)

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Research

24 pages, 6716 KB  
Article
In-Situ Infrared Camera Monitoring for Defect and Anomaly Detection in Laser Powder Bed Fusion: Calibration, Data Mapping, and Feature Extraction
by Shawn Hinnebusch, David Anderson, Berkay Bostan and Albert C. To
Appl. Sci. 2026, 16(7), 3378; https://doi.org/10.3390/app16073378 - 31 Mar 2026
Viewed by 275
Abstract
Laser powder bed fusion (LPBF) is susceptible to defects arising from melt pool instabilities, spatter, heat accumulation, and powder spreading anomalies. In situ infrared (IR) monitoring can detect these issues; however, it typically generates large volumes of data that are costly to store [...] Read more.
Laser powder bed fusion (LPBF) is susceptible to defects arising from melt pool instabilities, spatter, heat accumulation, and powder spreading anomalies. In situ infrared (IR) monitoring can detect these issues; however, it typically generates large volumes of data that are costly to store and analyze. This work proposes a projection-based framework that directly maps in situ thermal measurements onto a three-dimensional (3D) voxelized part geometry, substantially reducing storage requirements while preserving spatial fidelity. In addition, several IR derived features are incorporated into a practical workflow for defect detection and process model calibration, including laser scan order, local pre-deposition temperature, maximum pre-scan temperature, and spatter generation and landing locations. For completeness, commonly used metrics such as interpass temperature, heat intensity, cooling rate, and relative melt pool area are extracted within the same unified processing pipeline. All features are computed using a consistent, reproducible Python-based implementation to streamline integration into routine monitoring and analysis tasks. Multiple parts are fabricated, monitored, and characterized to evaluate the proposed framework, demonstrating that the extracted features reliably identify process anomalies and correlate with observed defects. Full article
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13 pages, 3857 KB  
Article
A Study of the Corrosion Resistance of 316L Stainless Steel Manufactured by Powder Bed Laser Additive Manufacturing
by Juan Ignacio Ahuir-Torres, Andrew Burgess, Martin Charles Sharp, Tahsin Tecelli Öpöz, Sean P. Malkeson, Peter L. Falkingham, Robert I. Darlington and Samuel Tammas-Williams
Appl. Sci. 2024, 14(17), 7471; https://doi.org/10.3390/app14177471 - 23 Aug 2024
Cited by 6 | Viewed by 4700
Abstract
Commercially available 316L (1.4404) stainless steel is commonly used for industrial filtration due to its combination of good material properties, particularly its corrosion resistance, which is a critical factor for filters in corrosive (e.g., saltwater) environments. Recently, laser powder bed fusion (LPBF) has [...] Read more.
Commercially available 316L (1.4404) stainless steel is commonly used for industrial filtration due to its combination of good material properties, particularly its corrosion resistance, which is a critical factor for filters in corrosive (e.g., saltwater) environments. Recently, laser powder bed fusion (LPBF) has enabled new more complex and efficient filtration pieces to be manufactured from this material. However, it is critical to know how the corrosion resistance is affected by this manufacturing strategy. Here, the corrosion resistance of LPBF manufactured 316L stainless steel is compared with wrought 316L sheet. The corrosion of the samples in saltwater was assessed with asymmetric electrochemical noise, potentiodynamic polarisation curve, and electrochemical impedance spectroscopy. The samples before and after corrosion were examined with scanning electron microscopy and energy-dispersive spectroscopy. The LPBF samples had higher corrosion resistance than the sheet samples and were more noble. The corrosion resistance of the LPBF sample increased with time, while the wrought sample corrosion resistance reduced over time. The corrosion mechanism of both samples was stable with time, formed of a passive film process and a bared material process. This paper presents the first study about the temporal evolution of the LPBF 316L stainless steel corrosion mechanism. Full article
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