Metal Additive Manufacturing Conference - MAMC 2020

Laser metal deposition (LMD) is a preferred process for metal additive manufacturing due to its unique advantages in terms of build speed, flexibility, its capability to use multiple materials and its ability to deposit metal on non-flat surfaces. However, true 3D process on free-form surfaces require time-consuming programming or teach-in procedures. To overcome this, we have developed a technology which eliminates most of the conventional programming. Using laser profile scanners, free-form parts can be scanned inside the LMD machine. Software algorithms generate digital 3D models of the parts which are used for a subsequent, automated toolpath generation procedure. Depending on the application, different process chains may be used. For LMD coating processes, the 3D models are displayed on a PC screen and the user defines deposition areas and layer thicknesses with some mouse clicks. The software will then calculate all required LMD toolpaths automatically. For the generation of 3D structures on top of existing 3D parts, 3D CAD models can be loaded into the software. After merging them with the scan-based model of the initial part, again all toolpaths will be calculated to generate the required 3D volumes. Finally, a post processor generates the CNC code or robot control code. A built-in simulation visualizes the planned deposition process, allowing final checking of the process. After that, the processes can be immediately executed. Besides the time saving, this technology also improves the build quality significantly as human errors can be eliminated almost completely. We will present not only details regarding the processes, but also real applications examples such as LMD coating of excavator teeth, laser metal deposition on 3D cast parts or LMD on extrusion screws.