Direct Energy Deposition: Difference between revisions

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==Process description==
==Process description==
direct energy deposition is a combination of welding and additive manufacturing technologies. a high power heat source is used to deposit a feed stock directly onto the bed (typically welding it onto a sacrificial print bed). each layer is welded onto the last until the part is fully formed. typically the part must then be cut from the build plate.
[[File:Neart-net-shapes-applications-2-web.png|right|frameless|567x567px]]
Direct Energy Deposition (DED) combines welding with other technologies to produce parts through additive manufacturing. In this process, a high power heat source is used to melt and deposit a feed stock directly onto a plate (typically welding it onto a sacrificial print bed). Each layer is welded onto the last until the part is fully formed. The part must then be cut from the build plate, and post processed, usually through subtractive manufacturing such as milling, to produce a finished product.


DED also has the unique ability's to modify existing metal parts. it simply treats the old part as the print surface, and then any additions are built layer by layer as if printing a typical part.  
DED also has the unique ability to modify existing metal parts. By treating the old part as the print surface, it can build out new layers, similar to printing on a traditional build plate.  


==strengths==
== Strengths & Weaknesses ==


* industrial scaling. DED machines are often much larger then other print types allowing this means large scale metal parts to be created.
=== Strengths ===
* part modification DED has the ability to add additional features onto weldable metal parts.
* '''Industrial scaling''': DED machines are often much larger then other print types, enabling the production of fairly large parts.
* '''Part modification''': DED has the ability to add additional features onto weldable metal parts, allowing for the combination of different manufacturing technologies or repair of broken parts.


==weaknesses==
=== Weaknesses ===
*'''Surface finish''': Although the exact surface finish is dependent on the feed stocked, DED has very poor surface finish in general.
* '''High energy''': The constant melting of metal in the process uses very high amounts of energy.
* '''Post processing''': DED prints often need to be machined to fix geometries and surface finishes.
* '''HIgh Cost:'''


* surface finish although dependent on the feed stocked used, ded has very poor surface finish
== Machine Ranges ==
* high energy: because the constant melting of metal is required in the process ded uses very high amounts of energy
DED has the ability to make large parts out of metal, however the resolution is relatively low compared to other methods.
* post processing: ded prints often need to be machined to fix geometries and surface finishes.
{| class="wikitable"
{| class="wikitable"
!
!
!Low
!Worst
!High
!Best
|-
|-
|volume X/Y/Z (mm)
|Volume X/Y/Z (mm)
|
|200/200/200
|
|5080/2794/2794
|-
|-
|resolution (mm)
|Resolution (mm)
|.67
|1
| 1
| .67
|-
|-
|layer height (um)
|Layer Height (um)
|
|1000
|800
|800
|-
|-
|price ($)
|Price ($)
|
|Requires
|
|Quotes
|}
|}
==Technologies==
[[File:Optomec-cs250.webp|none|thumb|[https://optomec.com/lens-cs-600-system/ Lens cs 600]<nowiki/> ]]
There are a number of specific technologies that can vastly change to capabilities of a printer.
{| class="wikitable"
!Build volume
!Resolution
!Size xyz
!Power
!Price
|-
|600/400/400mm
|.67mm
|2800/2700/2450mm
|2kw
|Requires Quote
|}
[[File:Modulo 250.png|none|thumb|[https://addupsolutions.com/machines/ded/ modulo 250]]]
{| class="wikitable"
!Build volume
!Layer Height
!Resolution
!Size xyz
!Power
!Price
|-
|400/250/300mm
|800um
|.1mm
|386/389/458mm
|1kw
|Requires Quote
|}
==Categories of DED==
The two primary factors used to characterize DED printers is based on the type of feed stock and the type of energy source used to melt the parts
 
=== Feed type ===
* '''Wire fed''': Wire feeding gives a consistent flow of material to the deposition pool. This Leads to similar problems that material extrusions printers experience such as the geometry being limted to the fixed diameter  of the material deposition, and a slight bulging causing bumpy surface finish
* '''Powder fed''': Powder methods enable more complex geometries to be produced by changing the amount of powder deposited in a particular area. However, not all material being deposited ends up being used, and a recycling system must be used to prevent powder waste.


=== Energy sources ===
* '''Laser''': Laser based DED systems allow for precise control over the heat source. Lasers paired with powder are capable of producing the most complex geometries in this category of AM.
* '''Plasma''': This tends to be the most energy efficient form of DED. Normally paired with wire feedstock, it is best suited for large scale manufacturing.
* '''Electron beam''': This is one of the less common energy sources for DED systems. It is very fast, however, it must be done in a vacuum, increasing costs, but reducing potential contamination of the parts.


'''Feed type''' the way that material is supplied to the heat source
== Technologies ==


* wire fed: Wire feeding will give a consistent flow of material to the deposition pool. This means that little material is wasted, but since the amount of material being deposited limits the complexity of parts available. this limited geometry also means that the surface finish is greatly affected.
* '''Wire Arc Additive Manufacturing (WAAM)''': The generic term for the combination of a plasma energy source and a wire feedstock.
* powder fed: when using powder methods not all material being deposited ends up being used. this means that the size of the deposition is variable allowing for complex geometries, but a recycling system must be used 
* '''Powder Laser (PL)''': The generic term for a combination of a powder feed source with a laser energy source.  
* '''Laser Engineered Net Shaping (LENS'''): A proprietary technology created by Optomec that combines a laser power source and a powder feeding system.
* '''Electron Beam Additive Manufacturing (EBAM'''): A proprietary technology created by Sciaky that combines an electron beam energy source, and a wire feedstock.  
* '''Rapid Plasma Deposition (RPD'''): A proprietary technology created by Norsk titanium that is an advanced version of WAAM.


==Navigation==
*[https://omic-am.mme.pdx.edu/index.php/Main_Page?veaction=edit Home page]
*[[Material extrusion|Material Extrusion]]
*[[Powder Bed Fusion]]
*[[Vat Polymerization]]
*[[Direct Energy Deposition]]
*[[Binder Jetting]]
*[[Material Jetting]]
*[[Sheet Lamination]]


'''energy sources'''
==References==
Rosen, Stucker, and Khorasani, Additive Manufacturing Technologies, chap. 10.


* laser: laser based ded systems allow for precise control over the hear source. when paired with powder feeding its best used when more complex geometries are needed.  
“Directed Energy Deposition - DED, LENS, EBAM | Make.” Accessed August 10, 2023. <nowiki>https://make.3dexperience.3ds.com/processes/directed-energy-deposition</nowiki>.
* plasma: due to the development of arc welding technology this tends to be the most energy efficient form of DED. normally paired with wiring feeding. it is best suited for large scale manufacturing.
* electron beam: this is one of the less common heat sources for DED systems. it is very fast, and because it must be done in a vacuum contamination is limited.

Latest revision as of 13:41, 24 October 2023

Process description

Neart-net-shapes-applications-2-web.png

Direct Energy Deposition (DED) combines welding with other technologies to produce parts through additive manufacturing. In this process, a high power heat source is used to melt and deposit a feed stock directly onto a plate (typically welding it onto a sacrificial print bed). Each layer is welded onto the last until the part is fully formed. The part must then be cut from the build plate, and post processed, usually through subtractive manufacturing such as milling, to produce a finished product.

DED also has the unique ability to modify existing metal parts. By treating the old part as the print surface, it can build out new layers, similar to printing on a traditional build plate.

Strengths & Weaknesses

Strengths

  • Industrial scaling: DED machines are often much larger then other print types, enabling the production of fairly large parts.
  • Part modification: DED has the ability to add additional features onto weldable metal parts, allowing for the combination of different manufacturing technologies or repair of broken parts.

Weaknesses

  • Surface finish: Although the exact surface finish is dependent on the feed stocked, DED has very poor surface finish in general.
  • High energy: The constant melting of metal in the process uses very high amounts of energy.
  • Post processing: DED prints often need to be machined to fix geometries and surface finishes.
  • HIgh Cost:

Machine Ranges

DED has the ability to make large parts out of metal, however the resolution is relatively low compared to other methods.

Worst Best
Volume X/Y/Z (mm) 200/200/200 5080/2794/2794
Resolution (mm) 1 .67
Layer Height (um) 1000 800
Price ($) Requires Quotes
Lens cs 600
Build volume Resolution Size xyz Power Price
600/400/400mm .67mm 2800/2700/2450mm 2kw Requires Quote
modulo 250
Build volume Layer Height Resolution Size xyz Power Price
400/250/300mm 800um .1mm 386/389/458mm 1kw Requires Quote

Categories of DED

The two primary factors used to characterize DED printers is based on the type of feed stock and the type of energy source used to melt the parts

Feed type

  • Wire fed: Wire feeding gives a consistent flow of material to the deposition pool. This Leads to similar problems that material extrusions printers experience such as the geometry being limted to the fixed diameter of the material deposition, and a slight bulging causing bumpy surface finish
  • Powder fed: Powder methods enable more complex geometries to be produced by changing the amount of powder deposited in a particular area. However, not all material being deposited ends up being used, and a recycling system must be used to prevent powder waste.

Energy sources

  • Laser: Laser based DED systems allow for precise control over the heat source. Lasers paired with powder are capable of producing the most complex geometries in this category of AM.
  • Plasma: This tends to be the most energy efficient form of DED. Normally paired with wire feedstock, it is best suited for large scale manufacturing.
  • Electron beam: This is one of the less common energy sources for DED systems. It is very fast, however, it must be done in a vacuum, increasing costs, but reducing potential contamination of the parts.

Technologies

  • Wire Arc Additive Manufacturing (WAAM): The generic term for the combination of a plasma energy source and a wire feedstock.
  • Powder Laser (PL): The generic term for a combination of a powder feed source with a laser energy source.
  • Laser Engineered Net Shaping (LENS): A proprietary technology created by Optomec that combines a laser power source and a powder feeding system.
  • Electron Beam Additive Manufacturing (EBAM): A proprietary technology created by Sciaky that combines an electron beam energy source, and a wire feedstock.
  • Rapid Plasma Deposition (RPD): A proprietary technology created by Norsk titanium that is an advanced version of WAAM.

Navigation

References

Rosen, Stucker, and Khorasani, Additive Manufacturing Technologies, chap. 10.

“Directed Energy Deposition - DED, LENS, EBAM | Make.” Accessed August 10, 2023. https://make.3dexperience.3ds.com/processes/directed-energy-deposition.

Retrieved from "https://omic-am.mme.pdx.edu/index.php?title=Direct_Energy_Deposition&oldid=265"