© Fraunhofer IAPT
The directed energy deposition (DED) process enables the production of metal components with near-final-contour shapes using a wide variety of materials. In particular, the directed deposition of material makes it possible to manufacture larger components at high deposition rates. We develop path planning strategies and additional system technology, and validate the processes for industrial use across our broad range of equipment.
Our team assists companies in integrating DED into their industrial production processes and in optimizing their use of DED. Our expertise and infrastructure enable users to achieve better results faster.
Our services include, among other things, consulting in the following areas:
Depending on the type of process, the DED method varies in terms of the type of filler material and the energy source. The material is fed into the process zone in powder or wire form and melted in a controlled manner by a laser or arc. A 3D component is created through the layer-by-layer build-up of multiple weld passes. The process head is manipulated by robots or CNC systems.
Fraunhofer IAPT possesses extensive DED expertise gained from research and industrial projects, as well as unrivaled equipment technology. Together with our industry partners, we identify the optimal DED process for specific requirements and applications.
DED Processes in Infrastructure at Fraunhofer IAPT
DED is an additive manufacturing process in which materials are deposited layer by layer through the directed application of material (powder or wire) and melted using a laser or electric arc. DED is ideal for large metal components requiring high deposition rates.
A near-net-shape approach is often used: A geometry is built up using DED with an allowance, and the final contour is then achieved, for example, through machining.
The Fraunhofer IAPT offers laser powder cladding (DED-LB/p), laser wire cladding (DED-LB/w), and arc wire cladding (DED-Arc/WAAM). These processes differ in terms of material form, energy source, and application, such as tailoring material properties or achieving high material utilization.
The Fraunhofer IAPT team advises companies on system engineering, application development, parameter sets, path planning, and sensor integration. The DED experts support the implementation in production and optimize the use of DED for industrial applications.
The materials used at Fraunhofer IAPT include Ti, Fe, Ni, and Al alloys, particularly Ti and titanium alloys such as Ti-6Al-4V for large-scale structures in the aerospace industry.
DED, when combined with conventional processes, reduces material and energy consumption, enables hybrid process chains, and delivers significant savings in titanium and energy.
Examples from Fraunhofer IAPT show material savings of 65% for certain titanium parts. Fraunhofer IAPT’s inert gas and shielding processes lower costs and reduce CO2 emissions.
A pilot line enables DED manufacturing and post-processing in a single setup, which saves time, reduces costs, and optimizes the aerospace process chain.
Fraunhofer IAPT uses in-process monitoring solutions that provide spatially resolved data, pinpoint anomalies in components, and reduce the effort required for testing.
