New experimental approach for local measurements of effective layer thickness, powder bed density and volumetric energy density to enhance metal laser powder bed fusion

This work presents an experimental approach for simultaneous measurements of effective layer thickness, powder bed density, and volumetric energy density, useful to improve the analysis of process dynamics and enhance precision in metal laser powder bed fusion. The approach is based on a special building platform, including removable inserts with reference geometries, and high-resolution X-ray computed tomography. The local variability in layer thickness and energy density are evaluated and used as indicators of process stability and energy transmission efficiency. The contextual measurement of powder bed density offers additional insights into potential process-related influences such as spatter formation and denudation.