Laser Metal Deposition – From coatings to large-scale 3D structures

Laser Metal Deposition (LMD) is an additive manufacturing process, which uses a laser beam as an energy source, focused upon a substrate through optics to generate a melt pool. Feedstock material is then added to the melt pool as powder or wire. The feedstock melts to form a deposit that is fusion bonded to the substrate. Using precise manipulation control of the deposition head and often combined with manipulation of the substrate, geometries can be built up in this way, layer by layer. LMD is commonly used across many different application spaces for coatings, repair, feature addition and 3D components. LMD belongs to a family of AM technologies defined by ASTM as directed energy deposition.

TWI utilises some of the latest developments in laser metal deposition, including emerging technologies such as EHLA (Extreme High-speed Laser Application) and coaxial wire deposition. TWI develops and adopts key software systems to help unlock the potential of the process. Within TWI’s holistic approach, smart toolpath and slicing software is utilised to generate precise, efficient deposition strategies. Coupled with these are advanced modelling and predication techniques, both are implemented into the development strategies of new components and materials, reducing timescales, resource requirements and material usage. TWI has been established in LMD technology for over ten years, for the applications of advanced materials and surface coatings, life-extending repairs, and for small to large-scale 3D components.