Powder Arc Fusion (PAF): An Arc-Based Powder Bed Fusion System Concept for Low-Cost Metal Additive Manufacturing

Abstract

Metal additive manufacturing has seen rapid growth, yet access remains limited by the high cost of established processes such as Selective Laser Melting (SLM), where entry-level systems typically require investments exceeding $100,000 USD. This paper introduces Powder Arc Fusion (PAF), a powder bed fusion concept that replaces the laser with a controlled electric arc as the energy source for metal powder melting, targeting system costs below $5,000USD and a desktop-compatible form factor. The PAF concept consolidates powder deposition, arc-based melting, and layer handling into a single integrated machine rather than a laboratory arrangement. The process is designed to operate within a sealed protective atmosphere and to allow layer thickness and melt track width to be varied within a single build, so that fine features and bulk volumes can be produced in one uninterrupted job. An analytical assessment of the melting energy requirements across more than 50 industrially relevant alloys indicates that the required thermal power is expected to remain within the range of a compact, low-cost power supply. The arc stability required for powder bed operation is intended to be provided by a proprietary arc control architecture developed at NeoFuse3D; its technical implementation is the subject of a dedicated forthcoming publication. The work presented here is at concept stage; no prototype has yet been built. The paper positions PAF against established powder bed fusion, wire arc additive manufacturing, and bound metal deposition, and identifies the application areas in which the concept is expected to be viable. PAF targets small and medium-sized enterprises, prosumer users, and research institutions that are currently excluded from metal additive manufacturing by cost and infrastructure barriers.