The EU-funded research project InShaPe has unveiled groundbreaking results that significantly enhance the efficiency, cost-effectiveness, and sustainability of metal additive manufacturing. Over three years, the consortium developed a novel process optimization approach that combines AI-based beam shaping with multispectral imaging (MSI) in laser-based powder bed fusion of metals (PBF-LB/M).
The project, coordinated by the Technical University of Munich (TUM) with ten partners across eight countries, received €7.2 million under the Horizon Europe framework program.
Sixfold Productivity Increase and 50% Cost Reduction
In industrial trials, InShaPe demonstrated productivity gains of over 600%, raising manufacturing rates from 15 cm³/h to 93.3 cm³/h. Production costs were slashed by 50%, while energy consumption and material wastage were significantly reduced. Component quality also improved, overcoming key barriers to large-scale industrial adoption.
The breakthrough was tested across five industrial demonstrators, including aerospace impellers, gas turbine parts, combustion chamber components, chainsaw motor cylinder heads, and satellite antenna components.
Intelligent Beam Shaping and Real-Time MSI Monitoring
At the heart of the innovation is AI-driven laser beam shaping, which adapts the laser profile to specific materials and geometries. Unlike traditional Gaussian beams, the ring-shaped beam profile produced a more stable melt pool, reducing defects such as cracking and spatter.
Simultaneously, the multispectral imaging system monitored thermal changes in real time, enabling early defect detection and corrective action. This integration ensures smoother processing, less rework, and faster throughput.
Industrial Adoption on the Horizon
The project marks a significant leap towards scalable series production in additive manufacturing, especially in aerospace, energy, and automotive sectors.
“Academic and industrial interest in our work is very high. We are delighted that this technology will soon be used in industrial systems, driving advances in process control, quality assurance, and application capabilities across sectors,” said Prof. Katrin Wudy, project coordinator at TUM’s School of Engineering and Design.
About InShaPe
Launched in June 2022, the InShaPe project ran until May 2025, supported by the European Union’s Horizon Europe program. Its mission was to transform laser-based powder bed fusion of metals into a commercially viable, resource-efficient production technology.
