The extensive use of the electron beam in manufacturing processes like welding or perforating
revealed the high potentials for also using it for solid freeform fabrication. First approaches like
feeding wire into a melt pool have successfully shown the technical feasibility. Among other
features, the electron beam exhibits high scanning speed, high power output, and beam density.
While in laser-based machines the fabrication is working in a stable way, transient physical
effects in the electron beam process can be observed, which still restrict process stability. For
instance, a high power input of the electron beam can result in sudden scattering of the metal
powder. The authors have developed an electron beam freeform fabrication system and examined
the above mentioned effects. Thus, the paper provides methods in order to identify, isolate and
avoid these effects, and to finally realize a reproducible process.Mechanical Engineerin