Laser powder bed fusion process feedback control based on in-situ powder layer thickness

Published

September 30, 2025

Author(s)

Jorge Neira Arango, Ho Yeung

Abstract

Metal laser powder bed fusion (LPBF) is a promising additive manufacturing technique for producing complex metal parts. However, the quality of the final product can be affected by various factors such as laser power, scanning speed, powder spreading quality, and layer thickness. In this study, we propose a real-time feedback control method based on the powder spreading quality and layer thickness. We employ a laser 3D scanner to measure the surface profile of each layer before and after the powder has been spread. A powder re-spreading will be triggered if an abnormality is detected on the spread powder surface. The difference between the profile is taken as the actual powder layer thickness and used to adjust the scan strategy for the next layer. The feedback control system is integrated into the customized-built LPBF testbed, and the effectiveness of the proposed feedback control system is demonstrated through a series of experiments. Overall, the proposed method has the potential to enhance the build quality and prevent build failures caused by the powder spreading issue.

Proceedings Title

Manufacturing Science and Engineering Conference (MSEC) 2025

Conference Dates

June 23-27, 2025

Conference Location

Greenville, SC, US

Pub Type

Conferences

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Keywords

Laser powder bed fusion, Powder layer thickness, Surface profile

Citation

Neira Arango, J. and Yeung, H. (2025), Laser powder bed fusion process feedback control based on in-situ powder layer thickness, Manufacturing Science and Engineering Conference (MSEC) 2025, Greenville, SC, US, [online], https://tsapps.nist.gov/publication/get_pdf.cfm?pub_id=958618 (Accessed January 14, 2026)