info@additive.co.in +91 9036369696
Home About Us Products Services Software Our Works Contact Us Contact Us

Understanding Laser Powder Bed Fusion (LPBF) — The Future of Metal Manufacturing

LPBF builds complex metal parts layer by layer using a high-powered laser that selectively melts metal powder. Unlock intricate, lightweight, and durable components that are hard or impossible with traditional methods.

Overview

What is LPBF?

Laser Powder Bed Fusion (LPBF) is an advanced metal additive manufacturing process. A high-powered laser selectively melts regions of a thin powder layer, building parts additively from a digital model with exceptional detail and performance.

Layer-by-Layer Precision

Each thin layer of powder (typically 20–100 μm) is precisely fused, enabling fine features and dense parts.

Complexity Made Practical

Create internal channels, lattice structures, and organic shapes without the penalties of conventional tooling.

High-Performance Metals

From titanium and nickel superalloys to tool steels—LPBF supports a broad portfolio of engineering materials.

How It Works

From Powder to Part

1) Spread Powder

A thin powder layer is spread across the build plate.

2) Selective Melting

The laser fuses areas per the 3D slice data.

3) Lower & Repeat

The platform lowers, a new layer is applied, and the cycle repeats until complete.

Detailed Workflow

Step-by-Step LPBF Process

CAD Model Design

The 3D CAD model defines the final part’s geometry and internal features.

Build Preparation

The model is sliced (20–100 μm). Supports and parameters (laser power, scan speed, layer thickness) are defined.

Printing (Additive Manufacturing)

  • Powder layer spread over the build platform.
  • High-power laser (e.g., fiber laser) selectively melts regions.
  • Platform lowers & next layer is printed.

Post-Processing

  • Remove parts & cut supports.
  • Heat treatment, HIP, surface finishing, machining as needed.

Inspection & Quality Control

Metrology, CT scanning, and material testing verify accuracy, strength, and internal quality.

Why LPBF

Advantages of LPBF

Go from idea to high-performance metal parts faster—with less waste and no tooling.

✅ Design Freedom
✅ Material Efficiency
✅ High Mechanical Properties
✅ No Tooling Required

Additive is not just a new tool—it’s a new way of thinking about how we design and produce metal parts.

Traditional Manufacturing

  • Requires tooling and molds
  • Multiple machining steps
  • Long lead times
  • High material wastage (subtractive)

Additive Manufacturing

  • Build directly from digital designs
  • Rapid design iterations
  • Reduced material & energy use
  • Geometric complexity without cost penalties
Use Cases

Applications of LPBF

Aerospace

Lightweight structural brackets, fuel nozzles, heat exchangers.

Medical

Patient-specific implants, orthopedic devices, surgical tools.

Tooling

Conformal cooling inserts and high-strength cutting tools.

Automotive & Motorsport

Turbocharger components and lightweight supports.

Energy

Turbine blades, burner heads, and oil & gas components.

Metals

Materials Used in LPBF

Each alloy family has tuned process parameters to achieve optimal density, microstructure, and mechanical performance.

Material Family Common Grades Key Properties
Stainless Steels 316L, 17-4PH Corrosion resistance, high strength
Titanium Alloys Ti-6Al-4V Lightweight, biocompatible, strong
Nickel-Based Alloys Inconel 718, 625 High-temp strength, corrosion resistance
Aluminium Alloys AlSi10Mg Low density, good thermal conductivity
Tool Steels H13, Maraging Steel High hardness, wear resistance
Our Platform

Why We Use TRUMPF TruPrint Systems

German-engineered precision for performance, repeatability, and industrialized workflows.

Performance

  • High-power lasers (up to 500W or 1kW)
  • Uniform powder deposition & thermal control
  • High-resolution optics for detailed features

Repeatability

  • Closed-loop process monitoring (melt-pool, exposure)
  • Consistent quality across builds
  • Integrated calibration & alignment

Automation

  • Automatic powder handling & sieving
  • Seamless unloading & post-process integration
  • Industry 4.0-ready connectivity

Explore the Future of Manufacturing with LPBF

From prototypes to production, LPBF enables what was once impossible. Have questions or need a quote? Let’s talk about your part, your material, and your timeline.

ISO 9001:2015 Certified