Laser powder bed fusion of metals (PBF-LB/M) has emerged as a leading additive manufacturing (AM) method for fabricating geometrically complex, high-performance metallic components, particularly those made from Ti-6Al-4V alloy. This contribution presents a comprehensive overview of the PBF-LB/M process, emphasizing its current research landscape and the persistent challenges in process design, particularly concerning the application of support structures and thermal management. Drawing on methods from welding science, a physically motivated framework is proposed to systematically analyze the thermal, mechanical, and metallurgical interactions that occur during fabrication. Special attention is given to the microstructural evolution of Ti-6Al-4V under PBF-LB/M conditions, highlighting the formation of acicular martensite and its behavior during the manufacturing process. The insights provided form a foundation for developing more efficient and reliable process strategies with practical relevance in industrial applications.      «

Laser powder bed fusion of metals (PBF-LB/M) has emerged as a leading additive manufacturing (AM) method for fabricating geometrically complex, high-performance metallic components, particularly those made from Ti-6Al-4V alloy. This contribution presents a comprehensive overview of the PBF-LB/M process, emphasizing its current research landscape and the persistent challenges in process design, particularly concerning the application of support structures and thermal management. Drawing on method...     »