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Despite its technological maturity, the productivity of powder bed-based laser melting of metals (PBF-LB/M) continues to be a major industrial obstacle to its widespread application. In addition to the use of multi-laser systems, laser sources with variable beam shaping and high output power are coming into focus, as they enable targeted control of energy input and the melt pool. Application-optimized beam distribution can significantly increase the layer build-up speed, resulting in a significant contribution to productivity gains. At the same time, however, new challenges arise with regard to process windows and component quality, redefining the limits of the process. The presentation will showcase current research results from the Institute for Production Management, Technology and Machine Tools (PTW), which investigate and evaluate the potential and process limits of beam shaping in PBF-LB/M.

About Jonathan Utsch:
Jonathan Utsch completed his Master of Science degree in Mechanical and Process Engineering at the Technical University of Darmstadt. Since 2023, he has been a research assistant at the PTW at TU Darmstadt, where he works on process development and beam shaping, with a particular focus on process monitoring of PBF-LB/M. Since September 2025, he has been co-managing director of the Technology Transfer Center – Additive Manufacturing Center at TU Darmstadt alongside Dr. Michael Krämer.