October 1, 2025

Size Effects on Process-Induced Porosity in Laser Powder-Bed Fusion Additive Manufacturing

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Keyhole porosity decreases as energy density reduces in laser powder-bed fusion processes, particularly in thin struts.
Porosity characteristics vary with strut sizes, showing that smaller struts typically have less keyhole porosity.
Micro-CT imaging effectively measures porosity in additive manufacturing applications, emphasizing its importance in quality assessment.
A strong correlation between scan lengths and porosity suggests need for optimized energy density to enhance small-scale fabrication.

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This analysis demonstrates keyhole porosity variations in thin struts via laser powder-bed fusion, highlighting energy density's critical role.

Habeeb et al. (2025) studied this question.

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This analysis demonstrates keyhole porosity variations in thin struts via laser powder-bed fusion, highlighting energy density's critical role.