Laser powder bed fusion (L-PBF) additive manufacturing is a process that utilizes a high-
powered laser to build near net-shaped parts in a layer-by-layer fashion using metal powder as the
feedstock material. Traditionally, the analysis of L-PBF produced parts has relied solely on post-
build characterization to understand the relationship between the printing process and the final
mechanical properties. Recent developments of in-process quality assurance systems, such as
Sigma Additive Solutions’ PrintRite3D, can measure in-process thermal signatures and melt pool
disturbances in real-time. This research aims to examine the relationship between process
parameters (e.g., scan strategy, scanning speed, and layer thickness) and in-process quality metrics
(IPQMs) captured by the PrintRite3D system on a Renishaw AM400. The mechanical response of
multiple part geometries (NIST residual stress bridges, single-arched bridges) and build materials
(Ti6Al4V) includes residual stress deflection and hardness; the results are compared with the
IPQMs.Mechanical Engineerin
