US Patent 11691218 Additive-manufacturing methods

The present disclosure provides methods of forming products using one or more lasers. In at least one aspect, a method for powder bed additive manufacturing includes defining a uniform pitch raster path for a laser traveling at a predetermined rate of travel. The raster path alternates back and forth within a strip width of less than 0.5 mm such that the laser's power density level is at least 80 percent of maximum power and the predetermined rate of travel yields a travel speed in the scan width direction of not less than 1,000 mm/s. The method includes depositing a layer of powder onto a substrate and causing the laser to solidify a quantity of the powder according to the defined raster path and the laser power setting.