In powder bed fusion of metal with laser beam (PBF-LB/M), repetitive melting and solidification of newly added layers lead to thermal stresses and distortions during part build-up. Particularly at critical component features such as unsupported overhangs, super-elevated edges pose a risk in terms of crashes with the recoating system during powder spreading. Damaged recoater lips lead to irregularities in the form of stripes in the powder bed. These local inhomogeneities cause lack-of-fusion porosity and geometric defects on the part surface. However, quantitative information on important quality aspects, such as tensile properties, dimensional accuracy, roughness, and hardness of parts printed under irregular powder bed conditions is scarce. Here, we show that samples from build jobs with recoater crashes maintain their elastic tensile properties and hardness, but lose elongation at break. Finite-element simulations of in-process distortions are used to design an artifact that intentionally damages the silicone rubber lip of the recoater but does not cause machine breakdown. The lowest mean yield strength of the damage-affected samples is 243 MPa, which is still within the material data sheet limits for AlSi10Mg. Therefore, recoater crashes do not necessarily result in rejects, but users must consider the likely presence of porosity.

Linear particle accelerators (Linacs) are primarily composed of radio frequency cavities (cavities). Compared to traditional manufacturing, Laser Powder Bed Fusion (L-PBF) holds the potential to fabricate cavities in a single piece, enhancing Linac performance and significantly reducing investment costs. However, the question of whether red or green laser PBF yields superior results for pure copper remains a subject of ongoing debate. Eight 4.2 GHz single-cell cavities (SCs) were manufactured from pure copper using both red and green PBF (SCs R and SCs G). Subsequently, the surface roughness of the SCs was reduced through a chemical post-processing method (Hirtisation) and annealed at 460 °C to maximize their quality factor ($Q_0$). The geometric accuracy of the printed SCs was evaluated using optical methods and resonant frequency ($f_R$) measurements. Surface conductivity was determined by measuring the quality factor ($Q_0$) of the SCs. Laser scanning microscopy was utilized for surface roughness characterization. The impact of annealing was quantified using Energy-Dispersive X-ray Spectroscopy and Electron Backscatter Diffraction to evaluate chemical surface properties and grain size. Both the SCs R and SCs G achieved the necessary geometric accuracy and thus $f_R$ precision. The SCs R achieved a 95% $Q_0$ after a material removal of 40 µm. The SCs G achieved an approximately 80% $Q_0$ after maximum material removal of 160 µm. Annealing increased the $Q_0$ by an average of about 5%. The additive manufacturing process is at least equivalent to conventional manufacturing for producing cavities in the low-gradient range. The presented cavities justify the first high-gradient tests.

Compared to conventional manufacturing, additive manufacturing (AM) of radio frequency (RF) cavities has the potential to reduce manufacturing costs and complexity and to enable higher performance. This work evaluates whether normal conducting side-coupled linac structures (SCCL), used worldwide for a wide range of applications, can benefit from AM. A unit cell geometry (SC) optimized for 75 MeV protons was developed. Downskins with small downskin angles $\alpha$ were avoided to enable manufacturing by laser powder bed fusion without support structures. SCs with different $\alpha$ were printed and post-processed by Hirtisation (R) (an electrochemical process) to minimize surface roughness. The required accuracy for 3 GHz SCCL (medical linacs) is achieved only for $\alpha >{45}^{\circ }$. After a material removal of 140 µm due to Hirtisation (R), a quality factor $Q_0$ of 6650 was achieved. This corresponds to 75% of the $Q_0$ simulated by CST^®. A 3 GHz SCCL concept consisting of 31 SCs was designed. The effective shunt impedance $Z{T}^2$ simulated by CST corresponds to $60.13\frac{\mathrm{M}\mathrm{\Omega }}{\mathrm{m}}$ and is comparable to the $Z{T}^2$ of SCCL in use. The reduction in $Z{T}^2$ expected after Hirtisation (R) can be justified in practice by up to 70% lower manufacturing costs. However, future studies will be conducted to further increase $Q_0$.

The enormous potential of additive manufacturing (AM), particularly laser powder bed fusion (L-PBF), to produce radiofrequency cavities (cavities) has already been demonstrated. However, the required geometrical accuracy for GHz $T{M}_{010}$ cavities is currently only achieved by (a) avoiding downskin angles $<{40}^{\circ }$, which in turn leads to a cavity geometry with reduced performance, or (b) co-printed support structures, which are difficult to remove for small GHz cavities. We have developed an L-PBF-based manufacturing routine to overcome this limitation. To enable arbitrary geometries, co-printed support structures are used that are designed in such a way that they can be removed after printing by electrochemical post-processing, which simultaneously reduces the surface roughness and thus maximizes the quality factor $Q_0$. The manufacturing approach is evaluated on two $T{M}_{010}$ single cavities printed entirely from high-purity copper. Both cavities achieve the desired resonance frequency and a $Q_0$ of approximately 8300.

Linear particle accelerators (Linacs) are essential for numerous applications in industry, medicine, and research. However, their use is often constrained by high investment costs, which are largely driven by conventional manufacturing methods. Studies have shown that additive manufacturing (AM) has the potential to significantly reduce these costs while simultaneously enhancing Linac performance. This study investigates this potential for the production of radio-frequency quadrupoles (RFQs), one of the most important Linacs for ion acceleration. For the first time, a multi-material RFQ prototype was fabricated using multi-material (MM) laser powder bed fusion (PBF-LB/M) AM, integrating the copper alloy CuCr1Zr for the internal cavity and tool steel (1.2709) for the outer shell in a single manufacturing step. The prototype’s design features six ConFlat® (CF) flanges for sealing without O-rings, highlighting the advantages of MM AM in simplifying assembly and enhancing functionality. Experimental evaluations included assessments of geometric precision, surface roughness, microstructural integrity, vacuum performance, resonance frequency (f_R), and quality factor (Q₀). The results demonstrated the successful application of MM PBF-LB/M for RFQ production, achieving a vacuum pressure below 8.3 ∙ 10^–8 mbar in the prototype. However, challenges in geometric precision and material transition zones necessitate further process optimization. This work underscores the potential of MM PBF-LB/M to address limitations in mono-material AM, particularly for Linac applications. Future developments, such as enabling pure copper processing and improving thermal and mechanical performance, could establish MM PBF-LB/M as a transformative technology for advanced Linac designs, paving the way for enhanced Linac applications.