Metal 3D Printing New Technology: AI-Driven Beam Shaping and Multispectral Imaging, InShaPe Generation Efficiency Increased Sixfold

Polar Bear has learned that the EU-funded InShaPe project has announced a major research breakthrough, successfully increasing the production efficiency of metal 3D printing by six times, while reducing manufacturing costs by 50%, significantly lowering energy consumption and material waste, and greatly improving the quality of components.

International Cooperation Bears Fruit

The InShaPe project, led by the Technical University of Munich (TUM), brings together 11 partners from 8 countries and has received 7.2 million euros in funding from the EU Horizon Europe program. After three years of intensive research and development, this consortium has successfully developed a revolutionary process optimization method for laser powder bed fusion metal (PBF-LB/M), perfectly combining AI-driven beam shaping technology with multispectral imaging (MSI).

Cylinder head of the engine of a handheld chainsaw

Technical innovation addresses industry pain points

The traditional PBF-LB/M process has unique advantages in manufacturing complex metal parts, but the rigid laser beam and outdated process monitoring often lead to high defect rates and severe energy waste. The InShaPe project has completely addressed these pain points through technological innovation.

The core breakthrough of the project lies in replacing the traditional Gaussian beam with an annular beam, which can be precisely adjusted according to the geometry and material properties of each component. This intelligent laser beam profile control creates a more stable molten pool environment, significantly reducing common defects such as cracks and spatter, while markedly improving processing speed and material utilization efficiency.

The introduction of multispectral imaging (MSI) systems adds another important function to this technology. MSI systems can capture thermal signals at different wavelengths to monitor the molten pool status in real time. Any process issues can be identified and located at the earliest moment, thereby immediately triggering corrective actions to minimize production delays and rework losses.

△Industrial gas turbine components used in the energy sector

Five major industrial application feasibility verification technologies

To verify the practicality of the technology, the project team conducted in-depth testing in five representative industrial application scenarios.

●Aerospace impeller

●Gas turbine components (made of Inconel 718 alloy)

Combustion chamber components in the energy field (CuCrNb material)

Handheld chainsaw engine cylinder head (AlSi10Mg aluminum alloy)

Satellite antenna components

The test results are remarkable: productivity increased from 15 cubic centimeters per hour to 93.3 cubic centimeters per hour, achieving a 6.2-fold improvement, while manufacturing costs were simultaneously reduced by 50%. These figures fully validate the effectiveness of the technology and its potential for industrialization.

Project Outlook

The success of InShaPe technology has made PBF-LB/M technology promising for application in industrial fields, especially in areas such as aerospace, energy, and automotive, where there is a strong demand for high-performance components. Project coordinator, Professor Katrin Wudy from the Technical University of Munich, stated that both academia and industry have shown great interest in this technology. It is expected that the technology will soon be put into industrial use and play an important role in improving process control and quality assurance.