Design and Calibration of the Fundamentals of Laser-Matter Interaction (FLaMI) Powder Bed Fusion Testbed at the National Institute of Standards and Technology

Published

February 21, 2025

Author(s)

David Deisenroth, Sergey Mekhontsev, Steven Grantham

Abstract

The advantages of additive manufacturing of metal components through laser-based powder bed fusion of metals (PBF-LB/M) have been increasingly embraced across a variety of industries and applications. But, broader adoption of this manufacturing technology requires that computational models and in-situ monitoring of such processes be experimentally validated under highly controlled conditions with advanced metrology. Such validation of models and in-situ monitoring systems are especially important for critical for applications that require qualification and certification. Such controlled conditions and advanced metrology cannot be readily implemented in commercial PBF-LB/M machines due to a variety of constraints and unknowns about machine performance. Therefore, a laboratory testbed has been develop to study the Fundamentals of Laser-Matter Interaction (FLaMI) at NIST. This paper outlines the materials and methods to develop such a system, as well as to accurately calibrate and characterize the machine performance.

Citation

Advanced Manufacturing Series (NIST AMS) - 100-66

Report Number

100-66

NIST Pub Series

Advanced Manufacturing Series (NIST AMS)

Pub Type

NIST Pubs

Download Paper

https://doi.org/10.6028/NIST.AMS.100-66

Local Download

Keywords

Metal additive manufacturing, laser powder bed fusion, machine qualification, process monitoring, laser beam metrology

Citation

Deisenroth, D. , Mekhontsev, S. and Grantham, S. (2025), Design and Calibration of the Fundamentals of Laser-Matter Interaction (FLaMI) Powder Bed Fusion Testbed at the National Institute of Standards and Technology, Advanced Manufacturing Series (NIST AMS), National Institute of Standards and Technology, Gaithersburg, MD, [online], https://doi.org/10.6028/NIST.AMS.100-66, https://tsapps.nist.gov/publication/get_pdf.cfm?pub_id=959358 (Accessed October 9, 2025)