Features and Capabilities

Optics Tower 

&TEMPS Module

100 μm FWHM

Laser spot

HIGH SPEED IMAGING of MELT POOL

Initial testing of the co-axial cameras . Ultimately, these

cameras will quantify melt pool size and intensity dynamics,

enable research in melt pool feedback control, and

potentially provide melt pool temperature values.

LASER SCAN CONTROL with AM-G CODE

• Custom laser scan controller allows position, velocity, and

power control at 100 kHz using xy2-100 protocol.

• Provides example of open-source control to promote LPBF

controller standardization.

Images taken before(left) and after (right) deposition of a scan line on a single 20 μm layer

of stainless steel powder, which show material ejection and denuding of powder

highlighted in green and red, respectively.

Before laser line scan After laser line scan

Before/After Denudation Before/After Ejected Particles

PART or POWDER SURFACE IMAGING

• In-situ layer-wise monitoring camera captures, measure, and quantifies

surface geometry or irregularities.

• High magnification of powder layer enables study of phenomena such as

denudation or particle ejecta.

Right: Example high mag

image of the melt pool,

taken with high speed,

FPGA controlled camera.

FPGA will provide fast

capture, measure, and

feedback to the laser

power/velocity control.

Example of particle ejecta phenomena captured at 50,000 frames/sec. These

higher frequency phenomena may not be captured at lower frame rates or

erroneously interpreted.

• For a 30 mm NIST 

logo, 425 G-code 

lines were 

interpreted into 

218,507 xy2-100 

lines.

• Different path and 

power strategies 

utilized in same 

scan strategy

Continuous path - constant power 

mode, 200 mm/s, at 75 W laser power

Constant build speed - constant density mode, 

600 mm/s, 225 W maximum laser power

Initial System Testing and Results

30 mm

PROTOTYPING SYSTEM

• Initial testing of the laser, optical components, and programming of controller

and user interface.

• Evaluate stability of optics, sensitivity of sensors, laser beam profile, etc.

Process Control 

Module 

Transfer Dolly

Allows removal of the main 

carriage for servicing, cleaning, 

or reconfiguration

Translating Carriage Gantry

Positions build area or radiometric 

calibration sources under the laser 

and co-axially aligned 

instrumentation

Process Chamber

Full vacuum and backfilling of inert gas, includes 

controlled & monitored recirculation and filtering.

Front Panel Doors

Hinged doors allow user access to build 

space, powder feed and build pistons, 

or cabling/instrumentation.

External Port for 

Offline Observation

Allows imaging of build area

Customizable port for externally 

mounted cameras/illumination.

Radiometric 

Calibration Sources

0.4 mm to 10 mm blackbody 

sources, reflectance standards, 

and reflectance sample heater 

which can be interrogated by 

the laser co-axial 

instrumentation

100 mm x 100 mm Build Area

Extendible area with coordinated motion of 

translating carriage gantry

Laser

Power: 500 W

Type: CW Multimode Yb Fiber

Wavelength: 1070 nm

Spot Size: 100 mm FWHM

Profile: Mixed Gaussian/Uniform

Rise Time: 57 ms at 50% power

XY Scanner Mirrors

Max Scan Speed: 10 m/s

Max Acceleration: 5 x 10

5 mm/s2

Granite Base

All metrology instruments are 

mechanically coupled to stable 

reference base.

Removable Panels

Customizable panels for 

cable/hose feedthroughs.

Hinged doors/panels for quick 

access to main carriage and 

build area.

Air Blanket Return

Can be removed for easier user 

access to build space

Powder Recoating Platform

Platform for exchangeable powder recoating types (flexible or 

stiff blade or roller). Available space for recoater-based 

instrumentation.

Laser safe 

viewports

Variable Focus Lens

Provides laser spot control & optimized 

melt pool imaging

500 Watt CW Yb Fiber Laser

Includes external power monitoring and capabilities 

for in-situ spot profile measurement 

Melt Pool Image (1x)

Diffraction-limited imaging performance at 

850 nm. Re-imaging lens allows extension 

of optics path for varying camera size 

50 mm dia. CA Laser scanner

100 kHz positioning control with well 

characterized geometric positioning accuracy 

mapped to build plane

Reflective Field Stop

Provides melt-pool monitoring during TEMPS 

system operation, 3x magnification 

Kinematic Posts

Main carriage is lowered onto 

kinematic mounts within 

chamber for repeatable 

positioning 

Main Carriage

Removable Splitter/Reflector

Exchangeable optic to allow back-emitted melt 

pool light into Process Control Module or 

TEMPS module

Fiber laser beam

850 nm beam for imaging

Leaked Fiber laser beam

(power monitor)

Collimator

Beamsplitter

Negative lens

Focusing lens

Scanners

Ar purge box

Laser window

Build Area

Imaging lens

Fold mirror

Melt Pool

Ejecta

Laminar Flow Air Blanket

Allows removal of the main carriage for 

servicing, cleaning, or reconfiguration

Build Area Platform

Includes powder feed bed, build bed, and 

overflow bin. Includes optional removable 

contamination chamber to limit stray 

debris.

AM Build Platform

Build Area: 100 mm x 100 mm

Build Height: 180 mm

Low Temp Build Plate: 80 °C

Hi Temp Build Plate: 400 °C

Environment Control

Vacuum: 10

-3 Torr

Recirculated Ar Purge

Scan/Laser Control

Power/speed control at 100 kHz