Munich, Germany –A groundbreaking leap in metal additive manufacturing (AM) has been achieved by the EU-funded project InShaPe, which has delivered a sixfold boost in productivity, cut production costs in half, and significantly reduced energy and material waste. Coordinated by the Technical University of Munich (TUM) and supported by ten partner institutions across Europe, the project marks a pivotal moment in transforming laser-based powder bed fusion of metals (PBF-LB/M) into a more scalable, sustainable, and affordable production method.
Launched in 2022 and backed by €7.2 million in Horizon Europe funding, InShaPe set out to revolutionize metal 3D printing by integrating AI-driven beam shaping and multispectral imaging (MSI). These technologies are reshaping the core of PBF-LB/M processes by improving precision, reducing defects, and speeding up production.
Intelligent Laser Control for Higher Speed and Better Quality
Traditional PBF-LB/M methods rely on a fixed Gaussian laser beam, often leading to inconsistencies such as cracking or overheating. In contrast, InShaPe’s AI-based beam shaping tailors the laser beam to each part’s geometry and material — often using a ring-shaped beam profile — for a more stable melt pool, fewer defects, and increased build rates.
Alongside this, the MSI technology monitors the melt pool in real time across multiple wavelengths, feeding thermal data back into the control system. This allows early defect detection and dynamic correction, minimizing delays and rework.
“We’ve demonstrated that beam shaping and real-time imaging are not just research concepts but scalable tools ready for industrial adoption,” said Prof. Katrin Wudy, InShaPe project coordinator and head of Laser-Based Additive Manufacturing at TUM.
From Aerospace to Automotive: Broad Industry Impact
The technology was successfully demonstrated in five demanding industrial use cases:
- Aerospace impeller (Inconel 718)
- Gas turbine part (Inconel 718)
- Combustion chamber component (CuCrNb)
- Chainsaw cylinder head (AlSi10Mg)
- Satellite antenna components
With build rates jumping from 15 cm³/h to 93.3 cm³/h, and cost reductions of 50%, InShaPe’s results represent a major stride toward series production in aerospace, energy, and automotive sectors.
A Model for Future Industrial AM
InShaPe paves the way for widespread industrial adoption of adaptive laser control and MSI-based quality monitoring, making metal AM faster, cheaper, and greener. As industries push for sustainable and high-performance manufacturing, these innovations are expected to play a central role in reshaping production lines.
