Powder bed fusion (PBF) of polymers is a collection of additive manufacturing processes that melt and fuse polymer in a powder bed. This article provides a complete suite of materials and processes involved in PBF of polymers. The discussion includes details of thermal and manufacturing issues, and safety, postprocessing, and finishing considerations, as well as of principal defects in PBF polymer parts and the mechanical properties of the parts produced by PBF. The article provides case studies on the applications of polymer PBF.

This article focuses on powder bed fusion (PBF) of ceramics, which has the potential to fabricate functional ceramic parts directly without any binders or post-sintering steps. It presents the results of three oxide ceramic materials, namely silica, zirconia, and alumina, processed using PBF techniques. The article discusses the challenges encountered during PBF of ceramics, including nonuniform ceramic powder layer deposition, laser and powder particle interactions, melting and consolidation mechanisms, optimization of process parameters, and presence of residual stresses in ceramics after processing. The applications of PBF ceramics are also discussed.

This article covers in-line process monitoring of the metal additive manufacturing (AM) methods of laser and electron beam (e-beam) powder-bed fusion (PBF) and directed-energy deposition (DED). It focuses on methods that monitor the component directly throughout the build process. This article is organized by the type of AM process and by the physics of the monitoring method. The discussion covers two types of monitoring possible with the PBF process: monitoring the area of the powder bed and component and monitoring the melt pool created by the laser or e-beam. Methods for layer monitoring include optical and thermal methods that monitor light reflected or emitted in the visible and infrared wavelengths, respectively. Monitoring methods for laser directed-energy deposition (DED) discussed are those that measure the size and shape of the melt pool, the temperature of the melt pool, and the plasma generated by the laser as it interacts with the molten metal.

This article focuses on a study that was performed to understand the effects of powder attributes; process parameters; and hot isostatic pressing (HIP) treatment on the densification, mechanical and corrosion properties, and microstructures of 17-4 PH stainless steel gas- and water-atomized laser-powder bed fusion (LPBF) parts at various energy densities. The results from the study showed the strong dependence of densification, mechanical properties, and microstructures on temperature, pressure, and time during the HIP cycle. The density, ultimate tensile strength, hardness and yield strength of gas and water-atomized LPBF parts increased due to HIP treatment and were higher than as-printed properties. The results also confirmed superior corrosion performance of the HIP treated LPBF parts.

Powder-bed fusion (PBF) is a group of additive manufacturing (AM) processes that includes selective laser sintering, selective laser melting, and electron beam melting. This article explains the processes and parameters of PBF systems that are used for biomedical applications. It also presents the desirable properties of biomedical devices and the advantages of using PBF systems for biomedical applications.

According to International Organization for Standardization (ISO)/ASTM International 52900, additive manufacturing (AM) can be classified into material extrusion, material jetting, vat photo polymerization, binder jetting, sheet lamination, powder-bed fusion (PBF), and directed-energy deposition. This article discusses the processes involved in polymer powder 3D printing using laser fusion/ sintering and fusing agents and energy, as well as the thermally fused PBF. It provides information on polymer powder parameters and modeling, the powder-handling system, powder characterization, the flowability of powder feedstock, and polymer part characteristics. The article describes the types of polymers in PBF, the processes involved in powder recycling, and the prospects of PBF in AM. In addition, the biomedical application of polyether ether ketone (PEEK) is also covered.