Laser‐powder bed fusion (L‐PBF) is extensively adopted in the aerospace and automobile industries for producing metallic components. The L‐PBF process involves rapid melting and solidification of metallic powders using a laser source to produce dense parts. Most industrial L‐PBF systems use a fiber‐based laser source that emits a Gaussian beam distribution. However, the conventional Gaussian beam used in L‐PBF processes presents inherent limitations that can impact the quality and properties of the final products. This review aims to provide a theoretical background of laser beam shaping techniques and explores the application of alternative beam shapes in L‐PBF. It investigates how different beam profiles affect the melt pool geometry, process stability, productivity, mechanical properties, microstructure, and surface roughness of fabricated parts. Additionally, it discusses different types of beam shaping techniques and elements utilized to generate distinct beam shapes. Furthermore, different constraints and limitations that hinder the full exploitation of beam shaping are critically discussed. By analyzing the impact of beam shaping in L‐PBF, this review provides insight into optimizing the additive manufacturing process, enhancing part quality, and improving processing performance. It will also help readers to overview the research gaps, challenges, and promising future directions in laser beam shaping applications in L‐PBF.

Selective Laser Melting (SLM) has emerged as an innovative technique for additive manufacturing, offering design freedom and net-shaped fabrication of complex metallic components. A critical yet often overlooked aspect is the laser beam profile used in the SLM process, which influences the laser-material interaction and affects the quality and performance of the final parts. This study employs numerical modelling to simulate the lasermaterial interaction in SLM, aiming to elucidate the impact of varying beam shapes on the melt pool formation and its characteristics. This experimental validated model provides a comprehensive analysis of laser energy absorption, beam shaping, heat transfer, and solidification dynamics during the SLM process. This study also introduces a unique approach, utilizing an Intensity Factor (β) based on beam profile intensity, to ensure consistent energy supply across different beam shapes and enable fair comparisons. The study compares Gaussian, Donut, Top hat, and Bessel beam shapes. The results show that changes in the laser beam profile slightly affect the size of the molten pool, but significantly influence the temperature distribution. Top Hat and Donut beams have lower peak temperatures compared to Gauss and Bessel beams. These findings provide important insights into understanding laser beam shaping effects and improving SLM to improve part quality and performance.