Process Planning for Multi-Directional Laser-Based Direct Metal Deposition

Abstract

Laser-based direct metal deposition has demonstrated the capability to deposit metal along multiple directions. Suitable control of parameters, namely, the metal-powder feed rate, the traverse speed, and the laser power allow fabrication of a desired shape for a large family of parts. The capability to deposit material along multiple directions eliminates the requirement for support structures. However, accessing the point of deposition and manipulating the direction of deposition require a coordinated control of two kinematical systems; one is related to the deposition platform, whereas the other is related to the deposition head. The identification of the key challenges, a mathematical basis of the process, possible solutions, the subsequent process planning, and experimental results are the subjects of this article.