Design and analyses of powder deposition, gas flow, and productivity for a rotary laser powder bed fusion system

Abstract

This study presents the design of a novel rotary PBF-LB/M machine where the recoater and gas system rotate synchronously with laser exposure. Unlike previous setups, the rotating nozzle covers only part of the powder bed, enabling higher localized gas velocities. CFD simulations indicate that a fine-mesh square grid improves flow uniformity with minimal powder disturbance. An angled recoater design supports stable rotary powder deposition. Trial builds, in-process measurements, and analyses of timing and powder efficiency demonstrate the system's effectiveness for annular parts, offering a significant speed advantage over rectilinear designs.