A study published in MDPI Metals (August 2026) investigated the laser powder bed fusion (LPBF) process for Zr-2.5Nb alloy and identified the optimal parameter set: laser power 160 W, scan speed 1400 mm/s, layer thickness 30 μm, and hatch spacing 120 μm (volumetric energy density 31.7 J/mm³), followed by heat treatment at 800°C for 2 hours with air cooling. The heat treatment transformed the as-built acicular α' martensite into a coarsened lamellar α+β duplex structure (with β-Zr area fraction of ~6.0%), increasing uniform elongation from 4.02% to 6.94% (+73%) while maintaining excellent mechanical properties (yield strength 792 MPa, ultimate tensile strength 881 MPa). Zr-2.5Nb is a traditional material for nuclear reactor pressure tubes (CANDU-type) and corrosion-resistant chemical equipment (in acetic/hydrochloric acid environments), offering outstanding neutron transparency and corrosion resistance. However, systematic research on LPBF of Zr-2.5Nb has been scarce—primarily due to the high reactivity of zirconium alloy powders and the brittleness of LPBF-fabricated parts. This study is the first to establish a complete mapping of process window to microstructure to mechanical properties for LPBF Zr-2.5Nb, demonstrating that post-heat treatment at 800°C/2h can significantly improve ductility without notably compromising strength. This breakthrough addresses the key bottleneck of brittleness in LPBF-fabricated zirconium alloys and provides actionable process specifications for industrial adoption. For the nuclear industry, LPBF enables the integrated fabrication of complex internal flow channel components, replacing traditional multi-part welding processes and enhancing safety and reliability. The research team, from the Department of Mechanical and Materials Engineering at Queen's University in Canada, has extensive experience in additive manufacturing of nuclear materials. For powder buyers: Zr-2.5Nb falls under the specialty rare metal powder category, with very few global suppliers (e.g., ATI in the US, Framatome in France), and its price is significantly higher than conventional titanium alloy powders. As demand for additively manufactured zirconium components grows in nuclear and chemical sectors, this category may become a blue-ocean market for high-value-added powders. Domestic Chinese companies capable of producing zirconium alloy powders (e.g., Xi'an Sailong, AVIC Metel) should monitor early demand for LPBF zirconium powders in the nuclear industry.