Editor’s Pick: Software Suite Built for Directed Energy Deposition Additive Manufacturing

FormAlloy introduces DEDSmart, a software suite offering precise control over Directed Energy Deposition (DED) builds. It is designed to complement FormAlloy’s line of DED additive manufacturing machines.

The company says the suite provides digital twin capabilities for use in the DED process. This allows users to harness the data generated in the printing process for improving builds.

There are four modules in the suite: Data; Optical Monitoring; Dynamic Layer Selection; and Melt Pool Monitoring. Details are as follows:  

The DEDSmart Data module enables users to record all build parameter data to be used post-build to analyze the component and verify build quality. A playback feature allows specific steps or processes to be frozen and repeated.  

The Optical Monitoring module gives a live view into the DED melt pool. The live dynamic range image of up to 55 frames per second allows creation of videos for post-print playback and analysis. 

The Dynamic Layer Selection module enables layer-by-layer inspection. It is a closed-loop operation for monitoring geometric accuracy during the build process. A laser profilometer scans the build after each layer, providing fast and accurate non-contact inspection. The software can auto-adjust the build during the process. It provides point-cloud data for post-process analysis. 

The Melt Pool Monitoring and Control module interacts with the two melt pool variables in FormAlloy units. Size and temperature is monitored along the optical path of the laser. Using closed-loop operation for either variable, laser power can be adjusted in-situ to control heat input. 

The DEDSmart Suite is available directly from FormAlloy. 

Sources: Press materials received from the company and additional information gleaned from the company’s website.