Improving Shielding Gas Flow Distribution to Enhance Quality and Consistency in Metal Laser Powder Bed Fusion Processes

Shielding gas flow in metal Laser Powder Bed Fusion (PBF-LB/M) removes ejecta and byproducts from the build plate and the optical path, preventing laser interference and loss of part quality. Previous research conducted on an EOS M290 used Magnetic Resonance Velocimetry (MRV) to resolve the three-component, three-dimensional flow field and identified a region of recirculation below the lower vent. The present work demonstrates the correction of this recirculation through practical chamber modifications: raising the build platform and optical assembly, and redesigning the recoater and the lower inlet to reflect the new build plate position. MRV was leveraged to generate flow distribution maps and velocity profiles of the modified configuration, showing a marked change in the overall flow field. Plate scans across the build area characterized the impact of gas flow improvements on process response. Specimens from the original configuration showed progressively shallower melt pools toward the vent, whereas those from the modified configuration exhibited a ~10% higher average melt pool depth in the region most affected by prior recirculation. Qualification artifacts built under both conditions provided preliminary evidence of improved part performance via enhanced gas flow distribution. These results highlight potential benefits of uniform gas flow distribution across the build plate through simple EOS M290 chamber modifications.