Productivity‐Driven Optimization of Laser Powder Bed Fusion Parameters for IN718 Superalloy: Process Control, Microstructure, and Mechanical Properties

Inconel 718 (IN718) is a nickel‐based superalloy widely used in high‐temperature applications. While laser powder bed fusion (L‐PBF) enables the fabrication of complex IN718 geometries, its low productivity remains a significant barrier to industrial scaling. This study presents a systematic approach to enhance productivity in L‐PBF of IN718 by optimizing processing parameters within a defined energy density window. By carefully adjusting the laser power, scanning speed, and hatching distance, it is demonstrated that productivity can be improved by up to 62.4% with only a negligible increase in porosity (≤0.04%) compared to standard settings. A detailed microstructural and mechanical characterization confirms that the optimized process retains acceptable tensile strength, ductility, and density. Furthermore, a practical cost–time analysis quantifies the potential for significant manufacturing savings, providing industrially relevant insights. This integrated investigation offers a clear processing guideline for balancing productivity, quality, and cost in L‐PBF IN718, contributing transferable knowledge for efficient additive manufacturing production of critical components. This work advances the AM field by providing a quantified, experimentally validated process window that enables significant productivity gains while maintaining mechanical integrity in L‐PBF in IN718.