Process parameter optimization for enhanced mechanical performance in PBF-LB/M of AISI 316L using constant energy density

Laser powder bed fusion (PBF-LB/M) is an additive manufacturing technology (AM) for producing metal components with complex geometries. The mechanical properties of these components play an important role in their performance and functionality. This work has found the process parameters to achieve the optimal properties of AISI 316L stainless steel using SamyLabs Alba 300 system. A Design of Experiments approach was employed under a constant volumetric energy density constraint to identify optimal parameter combinations (laser power, laser frequency, scanning speed and hatching distance). Tensile testing and metallographic analysis show that even at fixed energy input, the material’s properties were still affected by the process parameters. Specifically, higher laser frequencies and reduced scanning speeds, combined with increased hatching distances, led to improved mechanical performance with a significant positive impact on tensile strength and hardness of the manufactured parts. The results demonstrate that laser frequency plays a critical role in melt pool dynamics. Optimal settings derived from this study provide a reliable guideline for enhancing part quality in PBF-LB/M processes and can be extrapolated to similar AM systems.