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FREEFORM

The Directed Energy Deposition (DED) process is commonly used to deposit "freeforms" of near-net-shape metal components, which are nearly 100% dense with mechanical properties comparable to wrought materials. Freeforms may be thin wall or thick masses of material (built to any thickness). Other similar terms for this process include additive manufacturing and 3D metal printing.

The process begins with a CAD file of the desired part. Next the CAD file is modified and processed by the system software where the tool path for the laser is generated. A target material (commonly referred to as a base plate) is required to start the build. The target base material may be incorporated into the final part or may simply be removed from the part when the freeform  is complete. The freeform process occurs in an inert environment that protects against oxygen pickup in the molten material. Heat treatments and CMM scans of the completed freeform builds may be required depending on the specific application. The largest freeforms deposited to date include up to 60 inches long and others up to 7 feet in height.

DED can manufacture components with high aspect ratio features such as structural components for aircraft bulk heads or spars, components with internal flow paths, or unique geometries that are nearly impossible for conventional machining. The cases below show a variety of DED freeforms. 

Common Applications.

The applications are numerous, and we are still finding new applications each day. 
  • Exhaust Ducts
  • Piping Ducting
  • Nozzles
  • Manifolds
  • Structural Framework
  • Cases with Flanges and Bosses
  • Combustion Components
  • Blades/Airfoils
  • Vane Packs
  • ​Inlets
  • Heat Shields
  • Long Internal Channels
  • Weldments on Piping
  • Near Net Forging Replacement
  • Gradients/ Multi-materials

Case Studies.

  • Picture
    DED produced IN 625 Nozzle during hot fire testing
    (click here for link to  NASA-MSFC paper)
  • Picture
    DED JBK-75 Nozzle during hot fire test
  • Picture
    DED Nozzle with manifolds welded

DUCTS

  • Picture
    IN 625 Dual Wall Duct - 6" (150 mm) diameter
  • Picture
    IN 625 Dual Wall Duct - 6" (150 mm) diameter
  • Picture
    DED Dual Wall Duct during deposition
  • Picture
    DED Dual Wall Duct during deposition
  • Picture
    DED Duct during deposition

​CASES

  • Picture
    DED produced IN 625 Nozzle during hot fire testing
    (click here for link to  NASA-MSFC paper)
  • Picture
    DED JBK-75 Nozzle during hot fire test
  • Picture
    DED Nozzle with manifolds welded
  • Picture
  • Picture
  • Picture

​LARGE FREEFORMS

  • Picture
    DED produced IN 625 Nozzle during hot fire testing
    (click here for link to  NASA-MSFC paper)
  • Picture
    DED JBK-75 Nozzle during hot fire test
  • Picture
    DED Nozzle with manifolds welded
  • Picture
  • Picture

MULTI-AXIS

  • Picture
    DED produced IN 625 Nozzle during hot fire testing
    (click here for link to  NASA-MSFC paper)
  • Picture
    DED JBK-75 Nozzle during hot fire test
  • Picture
    DED Nozzle with manifolds welded
  • Picture
  • Picture
Directed Energy Deposition (DED) Gradient
Gradient Blade
Directed Energy Deposition (DED) Gradient
Profile Blade
Directed Energy Deposition (DED) Gradient
Side View

Gradients

  • Bottom of blade begins with 100% IN 625
  • Transitioned to 100% Haynes 230
  • Blade finished with 100% IN 718
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​All Rights Reserved.

RPM Innovations, Inc.
500 Turbine Drive
Rapid City, SD 57703
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​PHONE: 1-855-554-7764
EMAIL: [email protected]
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    • 557XR
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  • Contact Us