Additive manufacturing and laser metals processing


Additive manufacturing (AM) allows fabricating monolithic metallic parts with intricate geometries, thereby enabling value increase of products. Due to the huge design freedom and accessibility of each layer, AM can be used to fabricate parts with complex mechanisms and tailored functionalities. Our aim is to develop, fabricate and characterize novel multifunctional parts by local modification of the microstructure or by multimaterial AM. We are studying e.g. different (re-)scanning strategies, AM with different laser wavelengths (near-IR, green), but also pulsed-lasers of different intensities and beam profiles.



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Key publications


  • P. Gh Ghanbari, R. Wrobel, B. Rheingans, T. Mayer, C. Leinenbach, E. Mazza, E. Hosseini, Advancing efficiency and reliability in thermal analysis of laser powder-bed fusion, International Journal of Mechanical Sciences. 260 (2023) 108583

  • R. Wróbel, P.G. Ghanbari, X. Maeder, E. Hosseini, C. Leinenbach, Microstructure formation in micron-scale thin-walled Hastelloy X samples fabricated with laser powder bed fusion, Prog Addit Manuf. (2023)

  • V. Kalyanasundaram, A. De Luca, R. Wróbel, J. Tang, S.R. Holdsworth, C. Leinenbach, E. Hosseini, Tensile and creep-rupture response of additively manufactured nickel-based superalloy CM247LC, Additive Manufacturing Letters. 5 (2023) 100119

  • V. Lindström, G. Lupo, J. Yang, V. Turlo, C. Leinenbach, A simple scaling model for balling defect formation during laser powder bed fusion, Additive Manufacturing. 63 (2023) 103431

  • I. Ferretto, D. Kim, M. Mohri, E. Ghafoori, W.J. Lee, C. Leinenbach, Shape recovery performance of a (V, C)-containing Fe–Mn–Si–Ni–Cr shape memory alloy fabricated by laser powder bed fusion, Journal of Materials Research and Technology. 20 (2022) 3969–3984

  • M. Schuster, A. De Luca, R. Widmer, X. Maeder, C. Leinenbach, Processability, microstructure and precipitation of a Zr-modified 2618 aluminium alloy fabricated by laser powder bed fusion, Journal of Alloys and Compounds. 913 (2022) 165346

  • S. Staroń, B. Dubiel, K. Gola, I. Kalemba-Rec, M. Gajewska, H. Pasiowiec, R. Wróbel, Ch. Leinenbach, Quantitative Microstructural Characterization of Precipitates and Oxide Inclusions in Inconel 625 Superalloy Additively Manufactured by L-PBF Method, Metall Mater Trans A. 53 (2022) 2459–2479

  • D. Kim, I. Ferretto, C. Leinenbach, W. Lee, 3D and 4D Printing of Complex Structures of FeMnSi-Based Shape Memory Alloy Using Laser Powder Bed Fusion (Adv. Mater. Interfaces 13/2022), Advanced Materials Interfaces. 9 (2022) 2270075

  • L. Del Giudice, R. Wróbel, A.A. Katsamakas, C. Leinenbach, M.F. Vassiliou, Physical modelling of reinforced concrete at a 1:40 scale using additively manufactured reinforcement cages, Earthquake Engineering & Structural Dynamics. 51 (2022) 537–551

  • M. Dalaee, E. Cerrutti, I. Dey, C. Leinenbach, K. Wegener, Parameters Development for Optimum Deposition Rate in Laser DMD of Stainless Steel EN X3CrNiMo13-4, Lasers Manuf. Mater. Process. 9 (2022) 1–17

  • I. Ferretto, D. Kim, N.M. Della Ventura, M. Shahverdi, W. Lee, C. Leinenbach, Laser powder bed fusion of a Fe–Mn–Si shape memory alloy, Additive Manufacturing. 46 (2021) 102071

  • E. Tosoratti, I. Incaviglia, O. Liashenko, C. Leinenbach, M. Zenobi-Wong, Additively Manufactured Semiflexible Titanium Lattices as Hydrogel Reinforcement for Biomedical Implants, Advanced NanoBiomed Research. 1 (2021) 2000031

  • N. Kalentics, M.O.V. de Seijas, S. Griffiths, C. Leinenbach, R.E. Logé, 3D laser shock peening – A new method for improving fatigue properties of selective laser melted parts, Additive Manufacturing. 33 (2020) 101112

  • Arabi-Hashemi, X. Maeder, R. Figi, C. Schreiner, S. Griffiths, C. Leinenbach, 3D Magnetic Patterning in Additive Manufacturing via site-specific in-situ Alloy Modification, Applied Materials Today 18 (2020) 100512
  • S. Griffiths, H. Ghasemi Tabasi, T. Ivas, X. Maeder, A. De Luca, K. Zweiacker, R. Wrobel, J. Jhabvala, R.E. Logé, C. Leinenbach, Combining Alloy and Process Modification for Micro-crack Mitigation in an Additively Manufactured Ni-base Superalloy, Additive Manufacturing 36 (2020) 101443
  • N. Kalentics, N. Sohrabi, H. Ghasemi Tabasi, S. Griffiths, J. Jhabvala, C. Leinenbach, A. Burn, R.E. Logé, Healing cracks in Selective Laser Melting by 3D Laser Shock Peening, Additive Manufacturing 30 (2019) 10081
  • S. Griffiths. M.D. Rossell, J. Croteau, N. Vo, D. Dunand, C. Leinenbach, Effect of Laser Rescanning on the Grain Microstructure of a Selective Laser Melted Al-Mg-Zr Alloy, Materials Characterization 143 (2018) 34-42
  • M. Le Dantec, L. Güniat, M. Leistner, R. Figi, D. Bleiner, M. Leparoux, P. Hoffmann, Impact of oxygen content in powders on the morphology of the laser molten tracks in preparation for additive manufacturing of silicon, Powder Technology 361 (2020) 704-710.
  • Lanfant, F. Bär, A. Mohanta, M. Leparoux, Fabrication of Metal Matrix Composite by Laser Metal Deposition - A New Process Approach by Direct Dry Injection of Nanopowders, Materials 2019, 12, 3584.