In the world of Laser Powder Bed Fusion (L-PBF), achieving the perfect balance between speed, precision, and material properties represents one of the industry’s most critical challenges. Parameter optimization—the fine-tuning of laser settings, scanning strategies, and process variables—is the key to unlocking the full potential of metal additive manufacturing (AM).

For high-performance industries like aerospace, automotive, and energy, these refinements aren’t just beneficial—they’re essential for success. Without proper optimization, manufacturers face serious risks:

• Inconsistent material properties leading to unpredictable part performance
• Excessive porosity compromising structural integrity
• Suboptimal surface quality requiring extensive post-processing
• Inefficient build times increasing production costs
• Higher rejection rates affecting the bottom line

Kanfit AM: A Success Story in Parameter Optimization

Our partner Kanfit AM has achieved remarkable results through their mastery of parameter optimization in L-PBF processes. By implementing advanced parameter strategies on the Nikon SLM®280 system with AlSi10Mg, they’ve elevated their manufacturing capabilities to new heights. Their experience clearly demonstrates how strategic parameter refinement delivers concrete benefits such as:

• Enhanced Part Density: by meticulously adjusting laser power and scan speed, Kanfit AM has minimized defects while significantly improving material properties. This optimization ensures parts meet the highest standards for structural integrity and performance.
• Minimized Porosity: through careful calibration of hatch spacing and layer thickness, they’ve produced parts with minimal internal voids—critical for applications where material consistency directly impacts functionality and safety.
• Improved Production Efficiency: strategic parameter adjustments have enabled faster build times without compromising quality, allowing Kanfit AM to meet growing demand while maintaining excellence.
• Superior Surface Finish: by implementing advanced scan strategies, they’ve achieved smoother surfaces that require less post-processing, saving time and resources while delivering superior aesthetics.

Navigating the Interconnected Challenges of Parameter Optimization

The path to optimization is complex, requiring manufacturers to balance multiple interconnected variables simultaneously. Successful parameter optimization involves addressing four critical challenges that directly influence each other:

Material-Specific Considerations

Each metal powder behaves uniquely under laser energy, with characteristics that affect all other optimization factors. For example, AlSi10Mg’s thermal conductivity influences both process stability and achievable build speeds. This interconnection demands extensive testing to identify optimal parameters for specific applications, creating a foundation for the entire optimization process.

Building on Process Stability

Once material parameters are established, maintaining consistency across multiple builds becomes the next crucial challenge. This stability is especially critical in serial production, where part-to-part variation must be minimized. Advanced monitoring and control systems work in concert with material-specific parameters to ensure repeatable results, directly impacting the speed-quality balance.

Balancing Speed and Quality

With material parameters and process stability addressed, manufacturers can then focus on optimizing production efficiency. Higher build speeds must be carefully balanced against quality requirements, as faster processing can potentially compromise part integrity. This balance requires manufacturers to make calculated trade-offs based on application requirements, leveraging the material and process insights gained in previous optimization steps.

Integrating Through Advanced Technology

Tying these challenges together requires AM systems with sophisticated parameter control capabilities. These systems must provide the flexibility to adjust for material variations, ensure process stability, and optimize speed-quality trade-offs—all while adapting to evolving production needs.

The Nikon SLM®280 has provided Kanfit AM with precisely this integration capability, enabling them to address all these interconnected challenges simultaneously. This comprehensive approach has allowed them to experiment, refine, and achieve exceptional results consistently across their manufacturing processes.

Advancing the Future of Metal AM

Kanfit AM’s optimization journey highlights the growing sophistication of additive manufacturing. As the industry continues to evolve, three elements become increasingly critical:

1. Advanced AM Systems: Platforms that offer precise parameter control and robust performance
2. Comprehensive Process Control: Software that enables fine-tuning across multiple variables
3. Expert Technical Support: Partnerships that provide guidance based on real-world experience

At Nikon SLM Solutions, we prioritize all three elements, working closely with customers to maximize their results. Our collaborative approach helps manufacturers like Kanfit AM push boundaries in lightweighting, complex geometries, and high-performance part production—making metal AM increasingly viable for serial manufacturing.

Kanfit AM’s success with the SLM®280 demonstrates how parameter optimization transforms manufacturing workflows. Whether you’re focused on improving part quality, increasing production efficiency, or exploring new materials, mastering your process parameters is the foundation of AM excellence.

Ready to optimize your additive manufacturing capabilities? Contact our team today to discover how our systems and expertise can help you achieve optimal performance in metal AM.