In-Situ Multimodal Imaging of LPBF: From Fundamental Physics to Advanced Scanning Strategies

Laser Powder Bed Fusion (LPBF) is evolving rapidly, but key process instabilities, such as melt pool fluctuations, vapor plume dynamics, and particle ejection, still limit its robustness and scalability. This webinar presents new insights gained through in-situ multimodal imaging using synchrotron X-ray, schlieren, and long-standoff microscopy. These techniques provide direct, time-resolved visualization of four-phase interactions and reveal the hidden physical mechanisms behind spatter, pore formation, and instability thresholds.

A particular focus is placed on dynamic beam shaping using oscillating scanning, which offers a powerful route to enhance mass transfer, stabilize melt pool behavior, and reshape the energy distribution on the fly. Attendees will learn how these advanced strategies can unlock higher productivity and enable better laser power scaling-critical for next-generation LPBF systems.

This session goes beyond what can be captured in papers or textbooks. It offers a rare opportunity to see inside the process in real-time, understand failure modes visually, and engage with an experimental approach that directly informs manufacturing strategies.

Subject Matter Level: Intermediate - Assumes basic knowledge of the topic

What You Will Learn:
• Visualize key LPBF phenomena using in-situ X-ray, schlieren, and optical imaging.
• Understand how oscillating scanning improves stability, mass transfer, and energy delivery.
• Apply insights to boost productivity and scale laser power in LPBF.

Who Should Attend:
• Researchers and engineers working on laser-based additive manufacturing.
• Professionals developing or optimising LPBF processes and hardware.
• Anyone interested in advanced imaging techniques for laser-material interactions.

About the Presenter: Ioannis Bitharas from Heriot-Watt University

Dr. Ioannis Bitharas is an Assistant Professor at the School of Engineering and Physical Sciences, Heriot-Watt University. He holds an EngD in Applied Photonics and specialises in laser-material interactions, additive manufacturing, and fluid dynamics. His research combines high-speed imaging, flow visualisation, and multiphysics modelling to advance understanding of plasma- and laser-driven processes. He has collaborated with industry leaders like BAE Systems and Renishaw, and academic institutions including Carnegie Mellon and Argonne National Laboratory. His recent work includes laser ablation studies at the European X-ray Free Electron Laser (EuXFEL), with applications in precision surgery and next-generation manufacturing.