Fig. 1. Composition of LPBF equipment and forming process. (a) Basic principle of LPBF equipment^[10]; (b) schematic of LPBF forming process^[11]; (c) weld bead formation in LPBF^[12]; (d) complex physicochemical phenomena in powder melting^[12]

Fig. 2. Examples of applications of LPBF technology in aerospace and biomedical fields. (a) Power door opening system (PDOS) bracket of GEnx-2B engine^[15]; (b) Ti6Al4V aircraft bracket^[16]; (c) cabin bionic partition parts^[17]; (d) lingual orthodontic bracket^[18]; (e) total knee replacement femur prosthesis^[18]; (f) porous proximal femoral prosthesis^[18]

Fig. 3. Pore types in LPBF. (a) Unfused pores^[26]; (b) gas pores^[24]; (c) keyhole^[25]

Fig. 4. Balling phenomena in LPBF process. (a) Relationship between solid‐liquid‐gas interfacial tension of melt and wetting angle^[27]; (b) metal spheroidization mechanism during LPBF process^[29]

Fig. 5. Types of residual stress formation mechanisms in metal additive manufacturing^[36]

Fig. 6. Hydraulic parts manufactured by MOOG using LPBF. (a) Actuator cylinder^[40]; (b) aero actuator manifold^[41]; (c) hydraulic cylinder in hydraulic flight control actuator^[41]

Fig. 7. Design methods of hydraulic valve block structure. (a) Arc transition and integrated design of manifold in integrated valve block based on finite element method^[42]; (b) load and deformation design in integrated valve block based on computational fluid dynamics^[43]

Fig. 8. Hydraulic valve blocks manufactured by LPBF. (a) Titanium alloy hydraulic integrated valve block developed by Liebherr^[44]; (b) direct drive servovalve developed by Domin Fluid Power^[45]; (c) aeronautical titanium alloy hydraulic manifold manufactured by Materials Solutions^[46]; (d) hydraulic valve block without cross drilling developed by Aidro^[47]

Fig. 9. Development of integrated hydraulic steering gear shell based on LPBF. (a) Original model design of steering gear shell; (b) mechanical interface determination; (c) topology optimization design of overall structure; (d) machining allowance design; (e) LPBF forming; (f) verification of product performance

Fig. 10. Development of fuel nozzles by GE using AM^[48]. (a) LPBF forming of fuel nozzles; (b) labyrinth-type complex flow channel on nozzle end; (c) performance test of fuel nozzles

Fig. 11. Development of integrated air refueling fuel hood by LPBF. (a) Original fuel hood model with redundant heavy mechanical connection structure; (b) fuel hood model with pneumatic edge integrated design; (c) lightweight airfoil structure using lattice structure; (d) fuel hood formed by LPBF

Fig. 12. Aviation aluminum alloy heat exchanger manufactured by traditional method and AM method^[49]. (a) Comparison of corrugated plate fin structure in traditional heat exchanger and internal structure of heat exchanger manufactured by AM method; (b) comparison of heat exchangers processed by traditional and AM methods; (c) comparison of performances of heat exchangers manufactured by two processes

Fig. 13. Development of integrated ejector by LPBF. (a) Original model of ejector; (b) structure optimization based on statics simulation and fluid dynamics simulation; (c) comparison of ejector components processed by traditional and AM processes