Shedding Light on the Future of Metal 3D Printing

NIST’s Brian Gutierrez spotlights a cutting-edge method that could reshape the future of metal 3D printing by harnessing the power of laser light reflections—known as caustics—during fabrication. 

In his feature, Gutierrez explains how these intricate light patterns, familiar to anyone who has watched sunlight ripple across a pool’s bottom, offer a direct window into the molten metal’s shape as it’s printed layer by layer. By capturing and studying these reflections, NIST scientists can identify defects in real time, such as “keyhole pores,” which are tiny but potentially catastrophic weaknesses that can emerge during the process.

The research, conducted using custom test beds equipped with reflective domes and high-speed imaging, enables unprecedented visualization of the chaotic melt pool environment within metal 3D printers. Gutierrez emphasizes that while this technology is not yet ready for commercial deployment, it lays the groundwork for next-generation monitoring tools that could make metal additive manufacturing more accessible, reliable, and cost-effective for American manufacturers—including small businesses and problem-solvers outside traditional factory walls. Through this work, Gutierrez not only highlights innovation in materials science, but also NIST’s commitment to strengthening American industry through transformative research.

For the full article, visit the NIST website. (link: https://www.nist.gov/blogs/taking-measure/laser-focused-how-light-reflections-could-revolutionize-3d-printing-metals).