Benchmark Part for Form, Fit and Functional Testing for the Laser Engineered Net Shaping (LENS) Process

The primary objective of this Phase II Project is to provide a viable additive manufacturing solution for producing high performance metal parts using the LENSO technology. To meet this objective several of the current limitations of the existing LENSO process need to be overcome. In particular, a method must be identified and developed to overcome limited overhang capabilities available through the current LENSO process, material deposition rates should be improved, energy requirements for the process should be significantly reduced and powder utilization should be improved. Three areas of concentration are proposed for this project to provide the necessary improvements required to meet the objective of this project. These areas include software development, laser technology evaluation and implementation and improved nozzle designs. Although the preliminary work proposed for each of these areas of concentration will be performed somewhat independent of the others areas, it is important to note that there is a strong linkage between the developments in each of these areas. As such, the second half of the project will focus on integrating the best solutions from each area of concentration into a single system that will push the LENSä process technology forward to meet the needs of TACOM.