Powder DED Introduction

Powder DED Introduction

Powder DED Technology Overview

Introduction to Powder Laser Energy Deposition and Cold Spray

Powder DED Technologies such as Powder Laser ED and Cold Spray are advanced manufacturing technologies that are used for the production of blanks, but also to repair or coat applications. Powder Laser Energy Deposition (ED), often referred to as Laser Metal Deposition (LMD), employ a focused laser to melt and fuse metal powders into a dense structure, while Cold Spray uses high-velocity particle deposition at relatively low temperatures, preserving material properties.

This course will provide you with a comprehensive overview of the two technologies. Before getting started, this section outlines the course goals, target group and structure as well as the process chain

DED-technologies

What you will find in this section

Course goals and target group

This course is tailored for engineers, designers, and professionals involved in Powder Laser Energy Deposition (LMD) and Cold Spray technologies. Its objective is to equip participants with the critical knowledge required to understand the capabilities, limitations, and applications of these advanced manufacturing processes. By mastering these concepts, participants will be empowered to make informed decisions in technology selection and part design.

Beyond its sequential structure, this course serves as a reliable reference for professionals working on AM projects, providing insights and actionable guidelines to support their work.

Course structure

The course is structured into the following sections:

1. Technology and Process Chain Deep Dive

This section begins with a comprehensive overview of the Powder Laser Energy Deposition and Cold Spray process chains. It includes a detailed exploration of their operating principles, key technologies, and critical parameters that impact part quality and performance.

2. Material Availability and Properties

Participants will learn about the range of materials that can be utilized in Powder DED processes. This section covers material properties, achievable part characteristics, and typical quality assurance methods. Additionally, it addresses common defects and how to mitigate them during production.

3. Design Process and Guidelines

The final section focuses on design strategies specific to Powder Laser ED. It provides a step-by-step approach to designing for these technologies, along with practical restrictions and guidelines to optimize performance. The section concludes with illustrative design examples from various industries, showcasing successful implementations of these technologies.

Powder DED Process Chain

From digital model to finished part

Data Preparation

  • Creation of 3D CAD geometry
  • G-Code based tool path programming in CAM software
  • Collision check for AM and machining process

Data Preparation

AM build process

  • Deposition via CNC handling system or robot
  • G-Depending on part geometry 5-axis manipulation necessary

Data Preparation

Machining

  • Recovery of manufactured geometry
  • G-Code based tool path programming in CAM software
  • Machining to final geometry

The Powder Directed Energy Deposition (DED) process chain simple compared to other metal AM technologies such as Binder Jetting, as it bypasses the need for debinding or sintering steps. This streamlined approach makes it an attractive option for certain applications.

However, the data preparation step can still demand significant effort, depending on the specific technology and supplier. This involves tasks such as geometry manipulation, tool path programming, and ensuring compatibility with the manufacturing system. Additionally, post-processing is always required to achieve the desired surface finish, dimensional accuracy, and mechanical properties, making it an indispensable part of the Powder DED workflow.

You can explore the process in greater detail by diving into the following sub-topics, accessible via the agenda on the left:

  • Data Preparation – Learn about the steps involved in preparing designs and tool paths for the Powder DED process.
  • Powder Laser Energy Deposition – Understand the core principles and supply chain of Powder Laser DED.
  • Cold Spray – Explore technology principles and its unique material deposition approach.

Even though machining is always required to achieve final components, we will not cover it in this course.