The additive manufacturing process can be a whole new idea if you have never applied it before. There are several types you can use for different purposes. In this article, we discuss the DED additive manufacturing process. Read on for comprehensive details.
DED Additive Manufacturing: What You Need to Know
Directed Energy Deposition additive manufacturing involves metal addition, whereby the energy source (Laser, Electron Beam, or Arc) is directed toward a substrate material or a plate. The material then comes into contact with wire or powder feedstock material and melts, thus leaving a deposited material on the substrate. An essential element in ensuring the precision of DED is the utilization of advanced imaging technologies, such as the Line Scan Camera. This high-tech camera system captures detailed images of the printing process in real time, enabling operators to monitor and adjust parameters on the fly. DED is also referred to as 3D laser cladding, laser metal deposition, or direct light fabrication. This is because its source of energy varies and the final use.
The energy source and directed material flow go hand in hand, creating metal layers with finite thickness and width. DED is the most preferred printing method because it has a higher deposition rate and can additively manufacture bigger sections.
The DED manufacturing process is known for its versatility and precision. One innovative technique within DED involves the use of a strong wire mesh screen, which plays an important role in improving structural integrity and allowing for more intricate designs. This method allows for the deposition of material precisely onto the mesh, forming complex geometries with utmost accuracy. By strategically positioning the wire mesh within the printing process, manufacturers can achieve great results, from building unique lattice structures to reinforcing critical components. The wire mesh serves as both a support and a guide, enabling the precise deposition of material layer by layer, resulting in high-quality printed parts.
Pros
- Builds higher density parts which contribute to its good mechanical properties.
- It enables easier geometry modification of existing parts.
- From multiple metals, you can create new materials.
- You can use this technology in repairing worn-out parts.
- It has made it easier to metal coat on existing parts.
Cons
- You cannot use support structures during the building process.
- This technology is expensive compared to others.
- DED parts have a low resolution and poor surface finish.
Types of Directed Energy Deposition
DED is grouped into the following categories;
- Electron-beam-based DED-it employs electron beam in melting of powdered material feedstock.
- Laser-based DED- this type uses the laser as its main energy source.
- Electric-arc-based or plasma DED- melts the wire by using an electric arc.
Applications of Directed Energy Deposition
Several industries have embraced the power of the Directed Energy Deposition. Some of them are;
- Aerospace
Directed Energy Deposition (DED) has proven to be an invaluable asset in the aerospace industry. This technology has enabled the repair and refurbishment of expensive aerospace components, extending their lifespan and reducing costs associated with replacements. Additionally, DED has opened up new design possibilities by allowing the production of complex geometries and lightweight structures, which are crucial in this industry’s pursuit of efficiency and performance.
- Medical
In the medical field, DED (Direct Energy Deposition) has transformed the way customized devices are made, providing an unprecedented level of precision and customization. One significant application is in creating linear actuators for medical devices. DED technology allows for the fabrication of intricate medical devices with linear actuators and internal channels for functions like drug delivery or cooling systems. This advanced level of complexity and functionality has greatly improved the capabilities of medical devices. If you’re interested in learning more about such actuators, here’s the one we used that you can find them on platforms like Actuonix Motion Devices.
- Rail
The rail industry has embraced DED as a means to extend the life of critical components and reduce maintenance costs. This technology has facilitated the repair and restoration of worn-out rail components, effectively increasing their service life. Furthermore, DED has enabled the production of custom-designed rail components with improved wear resistance and strength, ensuring optimal performance and safety on the rails.
- Oil and gas
In the demanding oil and gas industry, DED has proven to be a game-changer. This technology has been utilized in the repair and refurbishment of critical equipment, reducing downtime and associated costs. DED has enabled the production of components with improved corrosion resistance and high-temperature performance, essential for operating in harsh environments. Moreover, DED has facilitated the fabrication of specialized tools and equipment tailored for exploration and extraction activities.
- Marine
The marine industry has benefited greatly from the capabilities of DED. This technology has played a crucial role in the repair and maintenance of marine vessels, extending the lifespan of expensive components. Additionally, DED has been employed in the production of customized marine equipment, such as propellers and impellers, with optimized hydrodynamic properties for improved efficiency and performance.
- Defence
In the defense sector, DED has been adopted for the repair and refurbishment of military equipment, reducing downtime and extending their service life. This technology has enabled the production of specialized components with enhanced ballistic protection and thermal management capabilities, ensuring the safety and performance of critical defense systems. Furthermore, DED has been used in the fabrication of advanced munitions and weapon systems with tailored properties, providing a strategic advantage.
- Education
DED has found its way into educational curricula, providing hands-on training opportunities for students in additive manufacturing technologies. This technology has enabled the production of educational aids and demonstration models, facilitating better understanding of complex concepts. Moreover, DED has been used in the fabrication of specialized equipment for research and development activities in academic institutions, driving innovation and advancing knowledge.
- Automotive
The automotive industry has embraced DED for its ability to repair and refurbish components, extending their lifespan and reducing costs associated with replacements. This technology has enabled the production of customized automotive parts with improved strength, wear resistance, and weight reduction, enhancing vehicle performance and efficiency. Additionally, DED has facilitated the fabrication of prototypes and concept models, accelerating product development cycles in the highly competitive automotive industry.
- Robotics
In the field of robotics, DED has been utilized in the production of components with tailored properties, such as lightweight structures and high-strength materials. This technology has enabled the fabrication of customized end-effectors and grippers for specific robotic applications, improving functionality and task-specific performance. Furthermore, DED has been used in the repair and maintenance of robotic systems, reducing downtime and extending their service life, ensuring uninterrupted operation.
- Construction
The construction industry has benefited from the capabilities of DED in various ways. This technology has been employed in the repair and refurbishment of construction equipment, reducing maintenance costs and downtime. DED has enabled the production of customized construction components with improved wear resistance and strength, ensuring durability and longevity in demanding construction environments. Moreover, DED has facilitated the fabrication of specialized tools and equipment for construction activities, such as demolition and earthmoving, enhancing productivity and efficiency on job sites.
Conclusion
In our opinion, being among the seven categories of additive manufacturing processes, Directed Energy Deposition is the best for creating complex shapes and large parts. The steps involved in this technology during the building of parts are simple and easy to understand. With its application in various fields, there is no need to doubt whether to use it or not.
