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Advances in Powder Bed Fusion Technologies
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Advances in Powder Bed Fusion Technologies

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: 31 October 2025 | Viewed by 3016

Special Issue Editor

Dr. Xiaoyu Liang

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China
Interests: powder bed fusion; hybrid manufacturing; simulation; fatigue

Special Issue Information

Dear Colleagues,

Powder bed fusion (PBF) technology has experienced rapid development in the last decade.

PBF technology has been successfully applied to a wide range of material systems, such as metals, polymers, ceramics, etc., of which the processing capabilities and quality show advantages to traditional processing routes. In the meantime, with the deepening of this research and the continuous demands of the industry, many innovative concepts have emerged, such as energy-field-assisted manufacturing, multi-material manufacturing, (laser) beam shaping, and hybrid additive/subtractive manufacturing. Besides those conceptual improvements, advances in PBF technologies are reflected in various aspects, including novel design and modeling, equipment upgrades, the expansion of applicable materials, appropriate post-processing methods, process monitoring, and quality evaluation.

In this Special Issue, we aim to present a comprehensive collection of research articles, reviews, and short communications, so as to highlight recent advances with regard to powder bed fusion technologies. Suitable topics for this Special Issue include, but are not limited to, the following:

  • Novel materials fabricated by PBF technologies;
  • Energy-field-assisted manufacturing;
  • Hybrid additive/subtractive manufacturing；
  • Multi-materials processing with PBF technology;
  • Laser beam shaping;
  • Simulation of PBF process;
  • Novel structure design aiming at PBF process;
  • Post-processing aiming at PBF parts;
  • Process monitoring and control;
  • Properties evaluation;
  • Advances in electron beam powder bed fusion.

Dr. Xiaoyu Liang
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Journal of Manufacturing and Materials Processing is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1800 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • laser powder bed fusion
  • electron beam powder bed fusion
  • simulation
  • monitoring
  • hybrid manufacturing
  • multi-materials
  • field-assisted manufacturing
  • laser beam shaping
  • metals
  • ceramics
  • polymers

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Further information on MDPI's Special Issue policies can be found here.

Published Papers (3 papers)

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Research

14 pages, 68479 KiB  
Article
Design Guide for Hybrid-Additive Manufacturing of Inconel 718 Combining PBF-LB/M and In Situ High-Speed Milling
by David Sommer, Simon Hornung, Cemal Esen and Ralf Hellmann
J. Manuf. Mater. Process. 2025, 9(3), 88; https://doi.org/10.3390/jmmp9030088 - 10 Mar 2025
Viewed by 549
Abstract
As the correlation between design rules and process limitations is of the upmost importance for the full exploitation of any manufacturing technology, we report a design guide for hybrid-additive manufacturing of Inconel 718. Basic limitations need to be evaluated for this particular hybrid [...] Read more.
As the correlation between design rules and process limitations is of the upmost importance for the full exploitation of any manufacturing technology, we report a design guide for hybrid-additive manufacturing of Inconel 718. Basic limitations need to be evaluated for this particular hybrid approach that combines laser powder bed fusion (PBF-LB/M) and in situ high-speed milling. Fundamental geometric limitations are examined with regard to the minimum feasible wall thickness, cylinders, overhanging structures, and chamfers. Furthermore, geometrical restrictions due to the integrated three-axis milling process with respect to inclinations, inner angles, notches, and boreholes are investigated. From these findings, we derive design guidelines for a reliable build process using this hybrid manufacturing. Additionally, a design guideline for the hybrid-additive manufacturing approach is presented, depicting a step-to-step guide for the adjustment of constructions. To demonstrate this, a powder nozzle for a direct energy deposition (DED-LB/M) process is redesigned following the previously defined guidelines. This redesign encompasses analysis of the existing component and identification of problematic areas such as flat angles, leading to a new construction that is suitable for a hybrid-additive manufacturing approach. Full article
(This article belongs to the Special Issue Advances in Powder Bed Fusion Technologies)
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17 pages, 21663 KiB  
Article
Effect of Laser Energy on Anisotropic Material Properties of a Novel Austenitic Stainless Steel with a Fine-Grained Microstructure
by Yurong Wang, Buwei Xiao, Xiaoyu Liang, Jun Zhou and Feng Lin
J. Manuf. Mater. Process. 2024, 8(6), 298; https://doi.org/10.3390/jmmp8060298 - 22 Dec 2024
Cited by 1 | Viewed by 771
Abstract
Laser powder bed fusion (LPBF) provides a novel approach with high complexity and freedom for material processing and design, and its special thermal history endows the material with anisotropic properties. By adding micro-alloying elements Nb and Ti into conventional 316L, the anisotropy of [...] Read more.
Laser powder bed fusion (LPBF) provides a novel approach with high complexity and freedom for material processing and design, and its special thermal history endows the material with anisotropic properties. By adding micro-alloying elements Nb and Ti into conventional 316L, the anisotropy of the novel austenitic stainless steel fabricated by LPBF, which is related to the laser heat input, was investigated. The refined microstructure of this steel was further strengthened with in situ-generated Nb-, Cr-, and Ti-rich nanoprecipitates at a specific location. The heat input affects the material anisotropy, and a lower heat input leads to stronger anisotropy in this steel. The as-built parts at a low heat input in the horizontal and vertical planes exhibited finer microstructures compared to those fabricated at a high heat input. The epitaxial growth of the grains associated with the thermal gradient resulted in the vertical-section grain size being generally larger than that of the horizontal section. As a result, the low-heat-input parts with a finer grain are also stronger in the horizontal direction, with yield and tensile strengths approaching 0.9 and 1.2 GPa, respectively. Meanwhile, the microstructural changes due to the high heat input imparted a better ductility of parts in different sections (a 3.15% and 4.4% increase in the horizontal and vertical directions, respectively). Its mechanical properties depend mainly on the direction of stress coupled with intergranular friction during deformation in both coarse and fine grains. Full article
(This article belongs to the Special Issue Advances in Powder Bed Fusion Technologies)
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15 pages, 2867 KiB  
Article
Analytical Prediction of Multi-Phase Texture in Laser Powder Bed Fusion
by Wei Huang, Mike Standish, Wenjia Wang, Jinqiang Ning, Linger Cai, Ruoqi Gao, Hamid Garmestani and Steven Y. Liang
J. Manuf. Mater. Process. 2024, 8(5), 234; https://doi.org/10.3390/jmmp8050234 - 17 Oct 2024
Viewed by 1104
Abstract
For advancing manufacturing, arising AM, with an inverse philosophical approach compared to conventional procedures, has benefits that include intricate fabrication, reduced material waste, flexible design, and more. Regardless of its potential, AM must overcome several challenges due to multi-physical processes with miscellaneous physical [...] Read more.
For advancing manufacturing, arising AM, with an inverse philosophical approach compared to conventional procedures, has benefits that include intricate fabrication, reduced material waste, flexible design, and more. Regardless of its potential, AM must overcome several challenges due to multi-physical processes with miscellaneous physical stimuli in diverse materials systems and situations, such as anisotropic microstructure and mechanical properties, a restricted choice of materials, defects, and high cost. Unlike conventional experimental work that requires extensive trial and error resources and FEM, which generally consumes substantial computational power, the analytical approach based on physics is an exceptional choice. Understanding the relationship between the microstructure and material properties of the fabricated parts is a crucial focus in AM research. Texture is a vital factor in almost every modern industry. This study first proposed a physics-based model to foreshadow the multi-phase crystallographic orientation distribution in Ti-6Al-4V LPBF while considering the part boundary conditions due to the importance of part geometry in real industry. The thermal distribution obtained from this function operates as the information for the single-phase crystallographic texture model. In this model, we forerun and validate the orientations of single-phase materials utilizing three Euler Angles with the principles of CET and thermodynamics, as well as the intensity of the texture by approximating them with published results. Then, we transform the single-phase texture into a dual-phase texture in Bunge calculation, illustrating visualized by pole figures of both BCC and HCP phases. The tendency and appearances of both BCC and HCP phases in pole figures predicted agree well with the experimental results. This texture evolution model provides a new paradigm for future researchers to model the texture or microstructure evolution semi-analytically and save many computational resources in a real-world perspective. Others have not yet done this work about simulating the multi-phase texture in an analytical approach, so this work bridges the gap in this field. Furthermore, this paper establishes the foundation for future research on materials properties affected by microstructure or texture in academic and industrial environments. The precision and dependability of the results obtained through this method make it a valuable tool for ongoing research and advancement. Full article
(This article belongs to the Special Issue Advances in Powder Bed Fusion Technologies)
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