New Dual Laser LPBF Concept Could Enable Support-Free 3D Printing

A promising new dual laser Laser Powder Bed Fusion (LPBF) concept could dramatically reduce the need for support structures in metal 3D printing.

The Support Structure Problem

One of the most persistent challenges in LPBF is that surfaces angled less than 45 degrees from the horizontal typically require sacrificial support structures. These supports consume material, increase print time, and require post-processing to remove.

Dual Beam Approach

The new concept proposes using two lasers simultaneously: a micro spot precision laser for delicate overhang areas, while a higher-power beam handles bulk material deposition at faster speeds. This allows the system to optimize each laser for its specific task rather than compromising with a single beam.

By dedicating precise thermal control to the overhang regions where heat dissipation is most critical, the approach could enable truly support-free printing of complex geometries that currently require substantial support structures.

Industry Impact

If commercialized, dual laser LPBF systems could significantly reduce material waste, post-processing time, and part cost for components with complex internal geometries. The technology would be particularly valuable for aerospace, medical implants, and high-value industrial components where support removal is both time-consuming and risky.