From design to reality: Improving multimaterial powder bed fusion laser melting additive manufacturing via in-situ monitoring

Multimaterial additive manufacturing enables the fabrication of components that integrate materials with distinct properties, unlocking unprecedented opportunities for the optimization of functionally integrated mechanical parts. Combined with the design flexibility of additive manufacturing, this capability allows for the creation of innovative solutions tailored to specific performance requirements. A novel platform for multimaterial Powder Bed Fusion – Laser Melting (PBF-LM) has been recently presented with the aim of depositing up to three materials on the same layer to achieve multimaterial products. Despite its unprecedented potential, multimaterial LPBF brings several challenges to achieve high-quality components without flaws or defects. This study leverages real-time process monitoring to aid process parameter optimization for multimaterial LPBF, with a special focus on combining steel and copper alloys for space and energy applications.