Validated dimensionless scaling law for melt pool width in laser powder bed fusion

The melting process during laser powder bed fusion (LPBF) is accompanied by complex physical phenomena, which can be rarely scaled with acceptable effort to utilize the in component design obtain tailored mechanical properties adequate machine productivity. A constitutive law relating melt pool geometry parameters thereby plays an essential role practically fostering productivity and quality LPBF. In this work, we derive improved dimensionless scaling based on dimensional analysis characterize width, also capable of beam-size-dependent attenuation. Measurements from LPBF-produced specimens 3D phenomenological LPBF finite element simulations are performed batch validate derived law. regression presents correlation ?97–98% for simulated widths ?70–90% experimental measured ones, fabricated minimum strut thickness 113 ?m. After effective power calibrated attenuation, proposed extended beam-size independent, as demonstrated overall measurements simulation results, under different beam diameter, unified ?97%. It demonstrates feasibility controlled manufacturing designing producing thin-walled components thicknesses micrometer range.