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The widespread application of metal additive manufacturing (AM) is limited bythe ability to control the complex interactions between the energy source andthe feedstock material. Here we develop a generalizable process to introducenanoscale grooves to the surface of metal powders which increases the powderabsorptivity by up to 70% during laser powder bed fusion. Absorptivityenhancements in copper, copper-silver, and tungsten enables energy efficientmanufacturing, with printing of pure copper at relative densities up to 92%using laser energy densities as low as 82 J/mm^3. Simulations show the enhancedpowder absorptivity results from plasmon-enabled light concentration innanoscale grooves combined with multiple scattering events. The approach takenhere demonstrates a general method to enhance the absorptivity and printabilityof reflective and refractory metal powders by changing the surface morphologyof the feedstock without altering its composition.

High Absorptivity Nanotextured Powders for Additive Manufacturing