Which technology is the most suitable for mass production of metal parts? Comparison: NeuBeam vs. PBF-EB vs. PBF-Laser

In recent years, metal additive manufacturing (metal AM) has become a key technology in the aerospace, defence and energy industries.
Today, two approaches based on the principle of Powder Bed Fusion (PBF) metal powder sintering dominate the market. These technologies differ primarily in the type of energy source that heats and sinters the powder:

• laser (PBF-L)

• ,

  electron beam (PBF-EB).

Wayland Additive has developed and marketed a new generation of the NeuBeam electron beam process that opens up new possibilities for the use of additive metal manufacturing in industrial practice.

Each of these technologies has its own strengths and limitations that determine whether the process is suitable for prototyping, small batch production or full-scale mass production. This review compares traditional PBF-L and PBF-EB with the new NeuBeam technology.

PBF-Laser: high precision, but limitations for larger parts

PBF-L technology uses one or more lasers to sinter metal powder layer by layer.
Provides high resolution, excellent dimensional accuracy and a wide range of usable materials. It is particularly suitable for parts with fine geometries, topologically optimized structures and small to medium-sized components.

For larger parts and long build cycles, however, major limitations become apparent:

• significant temperature differences between the sintering area and the surrounding material → development of internal stresses and the possibility of deformation

• ,

  residual stresses often require subsequent heat treatment

• ,

  laser power and absorption efficiency limit the process for high-strength alloys.

Therefore, PBF-L is excellent for precision prototypes, small batches and detailed components, but less suitable for high volume mass production.

PBF-EB: higher productivity but limited process stability

The PBF-EB process uses an electron beam under vacuum to sinter metal powder without the risk of oxidation. It enables efficient processing of difficult materials, especially titanium alloys, Inconel and cobalt-chromium alloys. Compared to the laser process, PBF-EB is faster and less prone to residual stresses due to the higher process temperature.

However, it also has its limitations:

• the interaction of the electron beam with the powder layer can cause charging of the powder particles, leading to process instability

• ,

  therefore, pre-baking of the entire powder layer is necessary, creating a so-called sinter cake and requiring extensive post-processing

• ,

  the resulting surface quality is typically coarser and requires additional finishing operations.

PBF-EB is therefore suited where the mechanical strength and thermal stability of the material is a priority, rather than maximum precision or surface quality.

NeuBeam: a new generation of electron beam process

NeuBeam technology, developed by Wayland Additive, represents a major evolution of traditional PBF-EB. The main difference lies in the active neutralization of electrostatic charges in the powder, which prevents particle repulsion and allows a stable process even at high electron beam energies.

NeuBeam combines:

• process efficiency and electron beam compaction depth

• ,

  with the precision and fine control typical of laser systems.

The technology is implemented in the Calibur3 industrial system, designed for mass production:

• Build volume: 300 × 300 × 450 mm

• Layer thickness: 150 µm

• Electron source power: up to 5 kW at 60 kV

• Process temperatures: up to ~1000 °C (depending on material

• )

  No pre-baking of the powder layer required

Due to the elimination of electrostatic charging and more stable temperature conditions NeuBeam:

• significantly reduces internal stresses

• ,

  provides a uniform microstructure

• ,

  ensures consistent material density.

At the same time, it reduces construction and post-treatment time, making it a strong candidate for true mass production of metal components.

Technology comparison: key parameters

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Practical implications

NeuBeam is already demonstrating significant benefits in the aerospace and defense industry. It enables the production of large, thin-walled and thermally stressed parts without deformation and with excellent dimensional repeatability. Materials such as titanium, Inconel or tungsten can be produced without supports, with a homogeneous microstructure and mechanical properties comparable to forgings.

"NeuBeam enables designers and manufacturing engineers to work with materials that were previously virtually unavailable for additive manufacturing - while achieving productivity equivalent to true mass production."

DarrinDickinson, Wayland Additive

Conclusion: a steady path to industrial mass production

While PBF-L remains the standard for high-precision prototypes and PBF-EB is the established method for solid alloys with high temperature resistance, NeuBeam is moving the electron process into a new era of stable, repeatable and scalable industrial production.

By virtually eliminating the need for powder pre-baking, reducing internal stresses and enabling efficient processing of challenging materials - including tungsten and high-temperature superalloys - NeuBeam offers a unique combination of performance, precision and process reliability.

For the aerospace, defense and energy sectors, NeuBeam provides a practical path to full-scale mass production of metal parts that were previously difficult or impossible to produce using other methods.