Laser Powder Bed Fusion Processes in Additive Manufacturing
Summary
Laser Powder Bed Fusion (LPBF) is a layer-wise additive manufacturing technique in which a focused laser selectively melts and fuses successive layers of metal or polymer powder to build complex three-dimensional components. Following the deposition of a thin powder bed, a computer-controlled laser trace defines the cross-sectional geometry, melting particles into a dense solid upon rapid solidification. Key process parameters include laser power, scanning speed, beam diameter, hatch spacing and layer thickness; their interplay governs energy input, melt-pool dynamics and resultant microstructure. Control of energy density is critical to avoid defects such as incomplete fusion, porosity or excessive keyhole formation. Thermal gradients induced by rapid heating and cooling influence grain structure and residual stress, affecting mechanical performance. Ongoing research seeks to improve powder flowability, optimise energy absorption, refine thermal modelling and expand material portfolios. Advances in in-situ monitoring, multi-physics simulation and tailored powder coatings are enhancing process stability, reproducibility and part quality. LPBF has global significance for aerospace, automotive, medical and tooling industries, offering design freedom, material efficiency and reduced lead times. As researchers develop predictive models of laser–matter interaction and validate them through high-speed imaging and thermal measurements, LPBF is poised to deliver ever more reliable, high-performance components with bespoke geometries.
Research from Nature Portfolio
No recent Nature Portfolio content available.
Laser Powder Bed Fusion Processes in Additive Manufacturing publication trend
The graph below shows the total number of articles in laser powder bed fusion processes in additive manufacturing across all publications each year (not limited to Nature Index journals).
Technical terms
Laser Powder Bed Fusion (LPBF): An additive process that uses a laser to selectively melt layers of powder to form a solid part.
Melt pool: The localized volume of molten material created by the laser during each scan track.
Absorptivity: The fraction of incident laser energy absorbed by the powder or molten surface.
Keyhole melting: A high-energy regime in which deep penetration results from vapour-induced cavity formation.
Heat conduction melting: A lower-energy melting mode dominated by conductive heat transfer in the solid and liquid.
Volumetric energy density: A metric combining laser power, scan speed, hatch spacing and layer thickness to quantify energy input per unit volume.
References
- An efficient ray tracing methodology for the numerical analysis of powder bed additive manufacturing processes. Additive Manufacturing (2023).
- Laser beam absorption measurement at molten metal surfaces. Measurement (2023).
- Absorbance study of powder conditions for laser additive manufacturing. Materials & Design (2022).
About these summaries
This Nature Research Intelligence Topic summary is created with the cited references and a large language model. We take care to ground generated text with facts, and have systems in place to gain human feedback on the overall quality of the process in line with our AI principles. We strive to create accurate and useful summaries for people unfamiliar with the research topic and that supports this goal. These pages are a beta release and will be updated as we learn how best to help people gain value from a research topic summary.
Turn complex research questions into confident strategic decisions
When you're under pressure to set direction, justify investment, or understand your competitive position, you need more than raw data — you need trusted insights you can act on.
Benchmark your performance against global peers using robust, methodologically sound analysis.
Combine quantitative metrics with qualitative expert insight to uncover strengths, gaps and emerging opportunities.
Gain tailored, decision-ready recommendations aligned to your strategic priorities.
Talk to us to learn more about our data dashboards and bespoke strategy reports.
Grow research skills, confidence and careers with training built for every stage of the research lifecycle.
Developed with Nature Portfolio journal Editors and internationally renowned experts. Discover three ways to learn:
Self-paced, online courses in convenient bite-sized units, covering key skills across scientific writing, publishing, grant writing, data analysis, and more.
Expert trainer-led workshops with hands-on exercises and real-time feedback across core research skills, delivered via interactive group sessions.
Editor-led workshops combining core principles in writing and publishing, personalised 1:1 feedback from Nature Portfolio Editors and hands-on exercises.
Explore course catalogues and workshop agendas, enquire about the options or request institutional pricing.