Productivity has always been one of the central conversations in metal additive manufacturing. Speed, power, and output dominate headlines, often framed as a race toward “more.” More lasers. More watts. More novelty.

But real progress in manufacturing rarely comes from chasing the loudest idea. It comes from understanding what actually happens in the process — and engineering accordingly.

Additive manufacturing is still a young industry, and waves of hype appear every few years. That is not a weakness; it is a sign of momentum. But as more companies move beyond prototyping and into production, the conversation is maturing. Today, success in AM is no longer defined by what is theoretically possible — it is defined by what delivers repeatable, reliable value on the factory floor.

Nikon SLM Solutions has lived through every phase of this evolution. From the early days of metal AM in the 2000s to today’s industrial-scale systems, each generation of technology has been guided by the same principle: turning promising ideas into sustainable productivity.

Beam Shaping: A Familiar Concept, Not a New Trend

Beam shaping has recently re-emerged as one of the most discussed topics in metal AM. Often framed as a breakthrough, it is presented as a solution to productivity challenges — a way to unlock higher build rates and better melt pool behavior.

The reality is simpler.

Beam shaping itself is not new. It has existed long before its recent resurgence in AM discussions, and it has been part of Nikon SLM Solutions’ systems for more than a decade.

As early as 2011, the SLM®280 DUAL combined a standard Gaussian laser with a high-power multimode laser — an unprecedented configuration at the time. What mattered most, however, was not the laser alone, but how it was used. By introducing the hull-core scanning strategy, customers could process the interior of a part with a larger beam for speed, while maintaining surface detail with a smaller beam at the edges.

The result was straightforward: higher productivity without compromising quality.

That philosophy still defines our approach today.

Engineering Flexibility Where It Matters

While much of the industry now focuses on introducing new laser modes, Nikon SLM Solutions took a different path early on. Instead of switching between predefined beam shapes, we engineered flexibility directly into the optics.

Through controlled defocus — and later, dynamic zoom optics on the NXG platforms — we enabled beam size to be adjusted mechanically, in real time, without changing the laser itself.

The distinction is subtle but important.

Rather than choosing between different beam “types,” the system adapts the optics to the process. This approach adds stability, avoids unnecessary complexity, and delivers consistent melt pool behavior even at very high laser power.

It is also why every laser and scanner in a Nikon SLM Solutions system undergoes extensive qualification. Optical stability, thermal behavior, and long-term performance are validated before a machine ever leaves the factory. Productivity only matters if it can be sustained.

Separating Hype from Production Reality

In recent years, Nikon SLM Solutions conducted extensive internal and external studies comparing different approaches to beam shaping. The conclusions were not surprising for those familiar with production environments.

At very small spot sizes and high power levels, porosity becomes a real risk. Increasing beam diameter — regardless of how it is achieved — leads to dense, stable material. This behavior is well understood in mature manufacturing processes.

What differentiates Nikon SLM Solutions is not whether beam shaping exists, but how long customers have been using it successfully. While others introduce new laser modes to compensate for architectural limitations, our systems have operated at high productivity levels for years using proven optical designs.

This approach also avoids additional system complexity and eliminates the need for bulky optical components that restrict power throughput. It is not about doing more — it is about doing what works, consistently, over time.

Proven in Production, Trusted by Industry

That maturity is one of the reasons leading manufacturers rely on Nikon SLM Solutions for demanding applications. Companies such as BMW and Brose have pushed the SLM®500 to its limits in series production. SAAB, Bosch, and Lockheed Martin trust NXG platforms for critical aerospace and defense programs where reliability is non-negotiable.

The introduction of zoom optics on NXG systems builds on this foundation, delivering stable melt pool behavior even at significantly higher input power. The goal is not novelty — it is control.

Productivity Is More Than a Laser

True productivity in metal AM cannot be reduced to laser power alone. What matters is power density across the build area, thermal stability, gas flow, and overall workflow efficiency.

NXG systems lead the industry in power per build area, and that capability only works because it is supported by robust optical design and chamber engineering. Features such as enhanced gas flow and optimized chamber height reduce sensitivity to spatter and fumes, enabling clean processing at high speeds.

Productivity also extends beyond the build itself. Exchangeable build cylinders — introduced already with the SLM®500 — allow production to continue while finished builds cool or undergo post-processing offline. It is a simple idea, but one that dramatically increases uptime.

The result is real-world productivity exceeding 1000 cubic centimeters per hour, measured across the entire process — not just laser exposure time.

Mastering Focus, Not Chasing Trends

From the first quad-laser SLM®500 to the NXG XII 600, Nikon SLM Solutions has consistently redefined what productivity means in metal additive manufacturing. The performance customers rely on today is the result of more than 15 years of engineering decisions made with long-term reliability in mind.

In an industry shaped by fast-moving trends, our philosophy remains unchanged. Productivity is not about following buzzwords. It is about mastering focus — shaping light in ways that deliver stable, repeatable results day after day.

We began with two-dimensional optics.
We evolved through three-dimensional control.
We matured with four-dimensional optical flexibility.

And the next chapter is already being written.