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Issue 053 - Winter 2008

Additive manufacturing of small metallic components

Author: Simon Sankaré and Didier Boisselier

Rapid manufacturing techniques have reduced the time to market of complex parts. IREPA LASER is experienced in this field; it has a patented coaxial powder cladding nozzle and has developed tools for rapid manufacturing of large metallic parts. This study describes the adaption of the process for the freeform manufacture of small structures and components.

Over the last few years, rapid manufacturing techniques (RMT) based on coaxial laser cladding process have been studied. In that they use simpler tooling and allow the production of complex shapes, they can provide a good alternative to machining or casting. The main applications of the process are:
• The addition of new profiles on existing or outlined parts.
• The manufacturing of parts with gradient of properties.
• The reparation of expensive machined or moulded parts

There are a number of commercial laserbased metal deposition processes (e.g. DMD™, LENS™), but for micro cladding the approach taken by IREPA LASER, a research centre, has been to adapt
its own patented nozzle design to create CLAD® (Construction Laser Additive Directe) a new form of metal deposition process.

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