Laser Powder Bed Fusion (LPBF), also known as PBF-LB, is a metal additive manufacturing process that uses a high-powered laser to selectively melt and fuse thin layers of metal powder according to a 3D CAD model. A fresh layer of powder is spread across the build plate after each pass, and the process is repeated layer by layer until the final component is produced. Laser Powder Bed Fusion is also commonly referred to as Direct Metal Laser Sintering (DMLS), Selective Laser Melting (SLM), Direct Metal Printing (DMP) and Metal 3D printing.

• Complex geometries – manufacture intricate features, internal channels and shapes that are difficult to machine.
• Design optimisation – use topology optimisation and lightweight structures to reduce mass while maintaining performance.
• Part consolidation – combine multiple components into a single manufactured part, reducing assembly and joining requirements.
• Rapid development – move quickly from CAD design to physical components, making LPBF particularly valuable for prototypes and R&D.
• Material efficiency – near-net-shape manufacturing can significantly reduce material waste compared with machining components from solid stock.
• Customisation – individual components can be modified without requiring major changes to the manufacturing setup.
• Performance-driven design – features such as conformal cooling channels, lattice structures and optimised flow paths can be incorporated directly into the component.