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<p>Inside-laser material feeding (IMF) technology is an emerging additive manufacturing approach in the field of laser additive manufacturing (LAM), featuring high material utilization rate, fine surface finish, and pollution-free working environment. This paper reviews the research progress of IMF from the aspects of structural design of laser internal processing devices, manufacturing processes, technical methods, and industrial applications. In terms of processing device structures, common types of laser beam spot, principles of optical transformation, and delivery methods are introduced. Additionally, the coupling modes of laser beams and materials are summarized, emphasizing that powder or wire is precisely delivered along the central axis of the laser beam. Regarding the internal laser manufacturing process, the influence of parameters on stability and roughness is discussed. Notably, IMF achieves atmosphere-free manufacturing capability for direct processing of active metallic materials (such as titanium, aluminum, and copper alloys) in ambient air by integrating a coaxial protective gas system with annular laser beam (ALB) design, completely eliminating the dependency on sealed chambers. This significantly reduces equipment costs and enhances process flexibility. Within the context of technologies and applications, the characteristics of various internal laser feeding heads and their practical uses in forming and coating-specific components are presented. For example, AISI 316L stainless steel components manufactured by IMF can achieve a hardness of up to 390 HV, and with a single powder utilization rate of 70–90%, outperforming the 60–80% of outside-laser material feeding (OMF), the utilization rate of wire even reaches up to 100%. Such high utilization directly contributes to improving process efficiency by minimizing material waste and reducing the need for post-processing. Finally, the development trends and future prospects of IMF technology are explored. IMF is poised to establish a unique pathway in laser additive manufacturing, enabling highly flexible and low-cost production.</p>

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Advances in inside-laser material feeding additive manufacturing technology

  • 期刊论文

  • 发表日期：

    2025年9月30日

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  • Jiaqiang Li,
  • Cheng Wang,
  • Yifei Wu,
  • Enxiang Fan,
  • Gangxian Zhu,
  • Xing Zhang,
  • Yibo Zou,
  • Shihong Shi

摘要

Inside-laser material feeding (IMF) technology is an emerging additive manufacturing approach in the field of laser additive manufacturing (LAM), featuring high material utilization rate, fine surface finish, and pollution-free working environment. This paper reviews the research progress of IMF from the aspects of structural design of laser internal processing devices, manufacturing processes, technical methods, and industrial applications. In terms of processing device structures, common types of laser beam spot, principles of optical transformation, and delivery methods are introduced. Additionally, the coupling modes of laser beams and materials are summarized, emphasizing that powder or wire is precisely delivered along the central axis of the laser beam. Regarding the internal laser manufacturing process, the influence of parameters on stability and roughness is discussed. Notably, IMF achieves atmosphere-free manufacturing capability for direct processing of active metallic materials (such as titanium, aluminum, and copper alloys) in ambient air by integrating a coaxial protective gas system with annular laser beam (ALB) design, completely eliminating the dependency on sealed chambers. This significantly reduces equipment costs and enhances process flexibility. Within the context of technologies and applications, the characteristics of various internal laser feeding heads and their practical uses in forming and coating-specific components are presented. For example, AISI 316L stainless steel components manufactured by IMF can achieve a hardness of up to 390 HV, and with a single powder utilization rate of 70–90%, outperforming the 60–80% of outside-laser material feeding (OMF), the utilization rate of wire even reaches up to 100%. Such high utilization directly contributes to improving process efficiency by minimizing material waste and reducing the need for post-processing. Finally, the development trends and future prospects of IMF technology are explored. IMF is poised to establish a unique pathway in laser additive manufacturing, enabling highly flexible and low-cost production.