Additive manufacturing, or 3D printing, is the building of 3D parts layer by layer. It includes multiple different processes. For a decade a promising process based on laser is leading the market for metal 3D printing : Laser-Powder Bed Fusion (L-PBF), or Selective Laser Melting (SLM). The powder is spread on a bed, and a laser is scanning the powder melting the it where the parts has to be constructed. SLM is now used in the industry, especially in the aerospace and automotive industry. Two main challenges have to be addressed by the SLM users and machine manufacturers : improving the process yield and processing new materials. This paper will focus on the processing of new materials, such as Ni-based super alloys, which are difficult to process due to hot cracking, which is the objective of the AMLABS project.

In the AMLABS project 3 different beam-shapers will be tested, this paper focuses on the first one : an elliptical beam-shaper. We describe the integration into an industrial SLM machine of a beam-shaper based on Multi-Plane Light Conversion (MPLC) technology. Indeed, specific beam shaping help managing the thermal gradient during the process, and allows the enhancement of the microstructure, reducing the residual stress and achieving a more fine and equiaxed microstructure. This reduces the risk of solidification cracking.

The beam shaper performance will be described, including the shaping quality over the Field Of View, as well as the process results on different materials and their mechanical performance analysis.