Study of the processing conditions for stainless steel additive manufacturing using femtosecond laser

The use of ultrashort-pulsed (USP) lasers in Additive Manufacturing (AM) enables the processing of different materials and has the potential to reduce the sizes and shapes manufactured with this technology. This work confirms that USP lasers are a viable alternative for Laser Powder Bed Fusion (LPBF) when higher precision is required to manufacture certain critical parts. Promising results were obtained using tailored and own-produced stainless steel powder particles, manufacturing consistent square layers with a series of optimized processing parameters. The critical role of processing parameters is confirmed when using this type of lasers, as a slight deviation of any of them results in an absence of melting. For the first time, melting has been achieved at low pulse repetition (500 kHz) and using low average laser power values (0.5–1 W), by generating heat accumulation at reduced scanning speeds. This opens up the possibility of further reducing the minimum size of parts when using USP lasers for AM.