Transferability of single-layer hatch package experiments to multi-layer builds in beam-shaped laser-based powder bed fusion of metals for efficient parameter development

Abstract Beam shaping introduces additional flexibility in laser-based powder bed fusion of metals (PBF-LB/M) by enabling spatially tailored energy distributions. However, this increased degree of freedom significantly expands the process parameter space and complicates parameter development. While hatch package experiments have been shown to provide representative melt track characteristics of multi-layer builds in Gaussian-beam PBF-LB/M, their applicability to beam-shaped PBF-LB/M remains unclear. In this study, the transferability of hatch package experiments to multi-layer builds is investigated for beam-shaped processes. Surface topography, surface classification, and melt track characteristics obtained from single-layer hatch package experiments are compared with corresponding measurements from multi-track experiments using cube specimens. A strong correlation between hatch package and cube data is observed, with most hatch package surface classifications matching the corresponding classifications obtained from cube specimens. Flat and Lack-of-Fusion ( LoF ) regimes show particularly strong agreement, while Bulging and Wavy morphologies exhibit systematic deviations attributed to layer-wise interactions. Furthermore, melt track dimensions derived from hatch package experiments capture the trends observed in cube measurements, with coefficients of determination relative to the identity line of 0.895, 0.756, and 0.693 for depth, width, and area, respectively. Only melt track area shows consistently higher values for the hatch package compared to the cube measurements. Qualitative comparisons further confirm a strong agreement in spatial surface features and melt track geometry. Overall, hatch package experiments provide an efficient approach for assessing surface topography and melt track characteristics in beam-shaped PBF-LB/M, while highlighting limitations associated with the propagation of surface irregularities during multi-layer build-up.