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Abstract Double raster scanning approach to 3D laser forming was investigated to obtain a large deformation with one-step laser irradiation, avoiding repetitive scanning. The magnitude of the deformation during raster scanning was found to be strongly dependent on the overlapping between adjacent passes, which can be controlled by changing their spacing and the beam diameter. Therefore, 3D deformation during raster scanning has been analyzed at various overlap ratios, whose effect on the temperature and strain distribution were discussed. As the heat transfer mode significantly influences the uniformity of the bending process, the variations in bending angles with negative and positive overlapping ratios have also been investigated. The ratio of the longitudinal and lateral curvatures decreased with the increasing overlap ratio. Therefore, the effect of the lateral side is more important for specifying the final symmetry of the part, playing a critical role in bending with higher overlap ratios. In a rectangular part, deformation of the lateral side was found to be more difficult, showing strong dependence on the length of the scanning track, compared with the space of the adjacent passes. Through process characterization, the double raster scanning process has been well understood and proved to be a feasible approach to 3D laser forming of rectangular parts.

A double raster laser scanning strategy for rapid die-less bending of 3D shape