--- _id: '62160' abstract: - lang: eng text: Laser powder bed fusion is a cornerstone technology for additive manufacturing (AM) of metals and polymers, yet challenges in achieving consistent reproducibility and process optimization persist. Addressing these requires a systematic understanding of the interactions between feedstock, process parameters, and final part characteristics throughout the entire production chain. This study presents results from a comprehensive interlaboratory investigation conducted by 32 research institutions, evaluating six feedstock, including nanoparticle‐modified aluminum alloy and polyamide powders, under standardized protocols. Data analysis encompasses 69 powder properties, 15 process parameters per print, and 78 part features, culminating in a dataset of over 1.2 million correlations. Advanced statistical methods and machine learning are employed to identify critical variability drivers, such as the impact of nanoparticle modifications on powder flowability and thermal conductivity, as well as the influence of process parameters on reproducibility. Newly introduced dimensionless figures of merit provide universal metrics to describe and predict thermal and mechanical interactions, simplifying process optimization and material characterization. The findings, supported by an open‐access dataset adhering to findable, accessible, interoperable, and reusable principles, advance understanding of material–process–structure–property relationships. They establish a benchmark for future research and lay the foundation for improving the reliability, quality, and sustainability of AM processes. article_number: '2402930' author: - first_name: Ihsan Murat full_name: Kuşoğlu, Ihsan Murat last_name: Kuşoğlu - first_name: Sunidhi full_name: Garg, Sunidhi last_name: Garg - first_name: Arvid full_name: Abel, Arvid last_name: Abel - first_name: Prasanna V. full_name: Balachandran, Prasanna V. last_name: Balachandran - first_name: Stephan full_name: Barcikowski, Stephan last_name: Barcikowski - first_name: Louis full_name: Becker, Louis last_name: Becker - first_name: Jan-Simeon full_name: Bernsmann, Jan-Simeon last_name: Bernsmann - first_name: Jonas full_name: Boseila, Jonas last_name: Boseila - first_name: Christoph full_name: Broeckmann, Christoph last_name: Broeckmann - first_name: Mert full_name: Coskun, Mert last_name: Coskun - first_name: Malte full_name: Dreyer, Malte id: '66695' last_name: Dreyer orcid: 0000-0001-9560-9510 - first_name: Mark full_name: East, Mark last_name: East - first_name: Mark full_name: Easton, Mark last_name: Easton - first_name: Nils full_name: Ellendt, Nils last_name: Ellendt - first_name: Stan full_name: Gann, Stan last_name: Gann - first_name: Bilal full_name: Gökce, Bilal last_name: Gökce - first_name: Mareen full_name: Goßling, Mareen last_name: Goßling - first_name: Joachim full_name: Greiner, Joachim last_name: Greiner - first_name: Piotr full_name: Gruber, Piotr last_name: Gruber - first_name: Moritz full_name: Grünewald, Moritz last_name: Grünewald - first_name: Kopila full_name: Gurung, Kopila last_name: Gurung - first_name: Nick full_name: Hantke, Nick last_name: Hantke - first_name: Florian full_name: Hengsbach, Florian id: '14073' last_name: Hengsbach - first_name: Hannes full_name: Holländer, Hannes last_name: Holländer - first_name: Brecht full_name: Van Hooreweder, Brecht last_name: Van Hooreweder - first_name: Kay-Peter full_name: Hoyer, Kay-Peter id: '48411' last_name: Hoyer - first_name: Yajiang full_name: Huang, Yajiang last_name: Huang - first_name: Florian full_name: Huber, Florian last_name: Huber - first_name: Olaf full_name: Kessler, Olaf last_name: Kessler - first_name: Burçin Özbay full_name: Kısasöz, Burçin Özbay last_name: Kısasöz - first_name: Stefan full_name: Kleszczynski, Stefan last_name: Kleszczynski - first_name: Ebubekir full_name: Koc, Ebubekir last_name: Koc - first_name: Tomasz full_name: Kurzynowski, Tomasz last_name: Kurzynowski - first_name: Arno full_name: Kwade, Arno last_name: Kwade - first_name: Simon full_name: Leupold, Simon last_name: Leupold - first_name: Dongmei full_name: Liu, Dongmei last_name: Liu - first_name: Felix full_name: Lomo, Felix last_name: Lomo - first_name: Arne full_name: Lüddecke, Arne last_name: Lüddecke - first_name: Gerrit A. full_name: Luinstra, Gerrit A. last_name: Luinstra - first_name: David A. full_name: Mauchline, David A. last_name: Mauchline - first_name: Fabian full_name: Meyer, Fabian last_name: Meyer - first_name: Lars full_name: Meyer, Lars last_name: Meyer - first_name: Peter full_name: Middendorf, Peter last_name: Middendorf - first_name: Stefan full_name: Nolte, Stefan last_name: Nolte - first_name: Michał full_name: Olejarczyk, Michał last_name: Olejarczyk - first_name: Ludger full_name: Overmeyer, Ludger last_name: Overmeyer - first_name: Andrij full_name: Pich, Andrij last_name: Pich - first_name: Sebastian full_name: Platt, Sebastian last_name: Platt - first_name: Felix full_name: Radtke, Felix last_name: Radtke - first_name: Roland full_name: Ramm, Roland last_name: Ramm - first_name: Silja-Katharina full_name: Rittinghaus, Silja-Katharina last_name: Rittinghaus - first_name: Richard full_name: Rothfelder, Richard last_name: Rothfelder - first_name: Johannes full_name: Rudloff, Johannes last_name: Rudloff - first_name: Mirko full_name: Schaper, Mirko id: '43720' last_name: Schaper - first_name: Marie Luise full_name: Scheck, Marie Luise last_name: Scheck - first_name: Johannes Henrich full_name: Schleifenbaum, Johannes Henrich last_name: Schleifenbaum - first_name: Michael full_name: Schmidt, Michael last_name: Schmidt - first_name: Jan T. full_name: Sehrt, Jan T. last_name: Sehrt - first_name: Yvonne P. full_name: Shabanga, Yvonne P. last_name: Shabanga - first_name: Alexander full_name: Sommereyns, Alexander last_name: Sommereyns - first_name: Rabea full_name: Steuer, Rabea last_name: Steuer - first_name: Layla Shams full_name: Tisha, Layla Shams last_name: Tisha - first_name: Anastasiya full_name: Toenjes, Anastasiya last_name: Toenjes - first_name: Christopher full_name: Tuck, Christopher last_name: Tuck - first_name: Adrian full_name: Vaghar, Adrian last_name: Vaghar - first_name: Bey full_name: Vrancken, Bey last_name: Vrancken - first_name: Zhengze full_name: Wang, Zhengze last_name: Wang - first_name: Sebastian full_name: Weber, Sebastian last_name: Weber - first_name: Jan full_name: Wegner, Jan last_name: Wegner - first_name: Bai-Xiang full_name: Xu, Bai-Xiang last_name: Xu - first_name: Yangyiwei full_name: Yang, Yangyiwei last_name: Yang - first_name: Duyao full_name: Zhang, Duyao last_name: Zhang - first_name: Evgeny full_name: Zhuravlev, Evgeny last_name: Zhuravlev - first_name: Anna R. full_name: Ziefuss, Anna R. last_name: Ziefuss citation: ama: 'Kuşoğlu IM, Garg S, Abel A, et al. Large‐Scale Interlaboratory Study Along the Entire Process Chain of Laser Powder Bed Fusion: Bridging Variability, Standards, and Optimization across Metals and Polymers. Advanced Engineering Materials. 2025;27(14). doi:10.1002/adem.202402930' apa: 'Kuşoğlu, I. M., Garg, S., Abel, A., Balachandran, P. V., Barcikowski, S., Becker, L., Bernsmann, J.-S., Boseila, J., Broeckmann, C., Coskun, M., Dreyer, M., East, M., Easton, M., Ellendt, N., Gann, S., Gökce, B., Goßling, M., Greiner, J., Gruber, P., … Ziefuss, A. R. (2025). Large‐Scale Interlaboratory Study Along the Entire Process Chain of Laser Powder Bed Fusion: Bridging Variability, Standards, and Optimization across Metals and Polymers. Advanced Engineering Materials, 27(14), Article 2402930. https://doi.org/10.1002/adem.202402930' bibtex: '@article{Kuşoğlu_Garg_Abel_Balachandran_Barcikowski_Becker_Bernsmann_Boseila_Broeckmann_Coskun_et al._2025, title={Large‐Scale Interlaboratory Study Along the Entire Process Chain of Laser Powder Bed Fusion: Bridging Variability, Standards, and Optimization across Metals and Polymers}, volume={27}, DOI={10.1002/adem.202402930}, number={142402930}, journal={Advanced Engineering Materials}, publisher={Wiley}, author={Kuşoğlu, Ihsan Murat and Garg, Sunidhi and Abel, Arvid and Balachandran, Prasanna V. and Barcikowski, Stephan and Becker, Louis and Bernsmann, Jan-Simeon and Boseila, Jonas and Broeckmann, Christoph and Coskun, Mert and et al.}, year={2025} }' chicago: 'Kuşoğlu, Ihsan Murat, Sunidhi Garg, Arvid Abel, Prasanna V. Balachandran, Stephan Barcikowski, Louis Becker, Jan-Simeon Bernsmann, et al. “Large‐Scale Interlaboratory Study Along the Entire Process Chain of Laser Powder Bed Fusion: Bridging Variability, Standards, and Optimization across Metals and Polymers.” Advanced Engineering Materials 27, no. 14 (2025). https://doi.org/10.1002/adem.202402930.' ieee: 'I. M. Kuşoğlu et al., “Large‐Scale Interlaboratory Study Along the Entire Process Chain of Laser Powder Bed Fusion: Bridging Variability, Standards, and Optimization across Metals and Polymers,” Advanced Engineering Materials, vol. 27, no. 14, Art. no. 2402930, 2025, doi: 10.1002/adem.202402930.' mla: 'Kuşoğlu, Ihsan Murat, et al. “Large‐Scale Interlaboratory Study Along the Entire Process Chain of Laser Powder Bed Fusion: Bridging Variability, Standards, and Optimization across Metals and Polymers.” Advanced Engineering Materials, vol. 27, no. 14, 2402930, Wiley, 2025, doi:10.1002/adem.202402930.' short: I.M. Kuşoğlu, S. Garg, A. Abel, P.V. Balachandran, S. Barcikowski, L. Becker, J.-S. Bernsmann, J. Boseila, C. Broeckmann, M. Coskun, M. Dreyer, M. East, M. Easton, N. Ellendt, S. Gann, B. Gökce, M. Goßling, J. Greiner, P. Gruber, M. Grünewald, K. Gurung, N. Hantke, F. Hengsbach, H. Holländer, B. Van Hooreweder, K.-P. Hoyer, Y. Huang, F. Huber, O. Kessler, B.Ö. Kısasöz, S. Kleszczynski, E. Koc, T. Kurzynowski, A. Kwade, S. Leupold, D. Liu, F. Lomo, A. Lüddecke, G.A. Luinstra, D.A. Mauchline, F. Meyer, L. Meyer, P. Middendorf, S. Nolte, M. Olejarczyk, L. Overmeyer, A. Pich, S. Platt, F. Radtke, R. Ramm, S.-K. Rittinghaus, R. Rothfelder, J. Rudloff, M. Schaper, M.L. Scheck, J.H. Schleifenbaum, M. Schmidt, J.T. Sehrt, Y.P. Shabanga, A. Sommereyns, R. Steuer, L.S. Tisha, A. Toenjes, C. Tuck, A. Vaghar, B. Vrancken, Z. Wang, S. Weber, J. Wegner, B.-X. Xu, Y. Yang, D. Zhang, E. Zhuravlev, A.R. Ziefuss, Advanced Engineering Materials 27 (2025). date_created: 2025-11-10T14:56:57Z date_updated: 2025-11-10T15:05:59Z doi: 10.1002/adem.202402930 intvolume: ' 27' issue: '14' language: - iso: eng publication: Advanced Engineering Materials publication_identifier: issn: - 1438-1656 - 1527-2648 publication_status: published publisher: Wiley status: public title: 'Large‐Scale Interlaboratory Study Along the Entire Process Chain of Laser Powder Bed Fusion: Bridging Variability, Standards, and Optimization across Metals and Polymers' type: journal_article user_id: '66695' volume: 27 year: '2025' ... --- _id: '33694' abstract: - lang: eng text: "Abstract\r\n The round robin test investigated the reliability users can expect for AlSi10Mg additive manufactured specimens by laser powder bed fusion through examining powder quality, process parameter, microstructure defects, strength and fatigue. Besides for one outlier, expected static material properties could be found. Optical microstructure inspection was beneficial to determine true porosity and porosity types to explain the occurring scatter in properties. Fractographic analyses reveal that the fatigue crack propagation starts at the rough as-built surface for all specimens. Statistical analysis of the scatter in fatigue using statistical derived safety factors concludes that at a stress of 36.87 MPa the fatigue limit of 107 cycles could be reached for all specimen with a survival probability of 99.999 %." author: - first_name: M. full_name: Schneider, M. last_name: Schneider - first_name: D. full_name: Bettge, D. last_name: Bettge - first_name: M. full_name: Binder, M. last_name: Binder - first_name: K. full_name: Dollmeier, K. last_name: Dollmeier - first_name: Malte full_name: Dreyer, Malte id: '66695' last_name: Dreyer orcid: 0000-0001-9560-9510 - first_name: K. full_name: Hilgenberg, K. last_name: Hilgenberg - first_name: B. full_name: Klöden, B. last_name: Klöden - first_name: T. full_name: Schlingmann, T. last_name: Schlingmann - first_name: J. full_name: Schmidt, J. last_name: Schmidt citation: ama: 'Schneider M, Bettge D, Binder M, et al. Reproducibility and Scattering in Additive Manufacturing: Results from a Round Robin on PBF-LB/M AlSi10Mg Alloy. Practical Metallography. 2022;59(10):580-614. doi:10.1515/pm-2022-1018' apa: 'Schneider, M., Bettge, D., Binder, M., Dollmeier, K., Dreyer, M., Hilgenberg, K., Klöden, B., Schlingmann, T., & Schmidt, J. (2022). Reproducibility and Scattering in Additive Manufacturing: Results from a Round Robin on PBF-LB/M AlSi10Mg Alloy. Practical Metallography, 59(10), 580–614. https://doi.org/10.1515/pm-2022-1018' bibtex: '@article{Schneider_Bettge_Binder_Dollmeier_Dreyer_Hilgenberg_Klöden_Schlingmann_Schmidt_2022, title={Reproducibility and Scattering in Additive Manufacturing: Results from a Round Robin on PBF-LB/M AlSi10Mg Alloy}, volume={59}, DOI={10.1515/pm-2022-1018}, number={10}, journal={Practical Metallography}, publisher={Walter de Gruyter GmbH}, author={Schneider, M. and Bettge, D. and Binder, M. and Dollmeier, K. and Dreyer, Malte and Hilgenberg, K. and Klöden, B. and Schlingmann, T. and Schmidt, J.}, year={2022}, pages={580–614} }' chicago: 'Schneider, M., D. Bettge, M. Binder, K. Dollmeier, Malte Dreyer, K. Hilgenberg, B. Klöden, T. Schlingmann, and J. Schmidt. “Reproducibility and Scattering in Additive Manufacturing: Results from a Round Robin on PBF-LB/M AlSi10Mg Alloy.” Practical Metallography 59, no. 10 (2022): 580–614. https://doi.org/10.1515/pm-2022-1018.' ieee: 'M. Schneider et al., “Reproducibility and Scattering in Additive Manufacturing: Results from a Round Robin on PBF-LB/M AlSi10Mg Alloy,” Practical Metallography, vol. 59, no. 10, pp. 580–614, 2022, doi: 10.1515/pm-2022-1018.' mla: 'Schneider, M., et al. “Reproducibility and Scattering in Additive Manufacturing: Results from a Round Robin on PBF-LB/M AlSi10Mg Alloy.” Practical Metallography, vol. 59, no. 10, Walter de Gruyter GmbH, 2022, pp. 580–614, doi:10.1515/pm-2022-1018.' short: M. Schneider, D. Bettge, M. Binder, K. Dollmeier, M. Dreyer, K. Hilgenberg, B. Klöden, T. Schlingmann, J. Schmidt, Practical Metallography 59 (2022) 580–614. date_created: 2022-10-11T13:15:48Z date_updated: 2023-01-04T14:48:17Z doi: 10.1515/pm-2022-1018 intvolume: ' 59' issue: '10' keyword: - Metals and Alloys - Mechanics of Materials - Condensed Matter Physics - Electronic - Optical and Magnetic Materials language: - iso: eng page: 580-614 publication: Practical Metallography publication_identifier: issn: - 2195-8599 - 0032-678X publication_status: published publisher: Walter de Gruyter GmbH status: public title: 'Reproducibility and Scattering in Additive Manufacturing: Results from a Round Robin on PBF-LB/M AlSi10Mg Alloy' type: journal_article user_id: '66695' volume: 59 year: '2022' ...