Taking a Powder

Abstract

This article focuses on the use of laser in conjunction with metal powder. The use of the laser in conjunction with metal powder could be regarded as an extension of rapid prototyping, which has involved plastic parts almost exclusively. However, terms such as ‘direct metal fabrication’ and ‘rapid manufacturing’ suggest that developers have much more ambitious goals in mind for powder metals. Lockheed Martin Tactical Aircraft Systems in Fort Worth, Texas, is operating a research facility based on the laser engineered net shaping (LENS) process on the same factory floor where the F-16 fighter is assembled for the US Air Force. Optomec Design Co. in Albuquerque builds machines for use with the LENS process. Tests of Sandia National Laboratories' laser engineered net shaping process take place in a tank at Lockheed Martin Tactical Aircraft Systems. Much can be done in direct metal fabrication to improve the thermal conductivity of tooling for injection molding and die casting. The result can be increases in cycle times of as much as 80 percent.