Diode Laser Technology for Directed Material Deposition (DMD) Processes

Direct Metal Deposition (DMDr) is a laser-based, layer additive, direct material deposition process capable of producing fully dense metal alloys from metal powder. It is self-monitoring, enabling 3-dimensional fabrication with minimal operatorintervention. The technology holds promise for repair and fabrication of damaged equipment on the battlefield. The state of the art is not field deployable due to the inefficiency and large footprint of the CO2 or Nd:YAG laser.Diode laser is semiconductor-based technology, having 5x efficiency of existing systems, reducing the footprint by 80%. The fast response time and short (810 micrometer) wavelength would enable increased deposition rate and enhanced dimensional accuracyover current systems. Spot-focused diode lasers are commercially available, enabling the exploratory development of a low-power diode laser DMD process.The Phase I program proposes a feasibility demonstration of a 250-Watt diode laser DMD process. The Phase I Option proposes to increase laser power to 500 Watts and study the deposition rate and dimensional accuracy achievable with the process. Commercialapplication of the process would enable high volume manufacturing of components with enhanced wear-resistant and corrosion-resistant surfaces, such as engine blocks, automotive drive train components and turbine blades. Commercial application of the process would enable high volume manufacturing of components with enhanced wear-resistant and corrosion-resistant surfaces, such as engine blocks, automotive drive train components and turbine blades.Also, table top, direct metal rapid prototype machines could be manufactured, enabling the creation of fully functional metal prototypes, having the full range of mechanical properties as the finished product.