IMTS Conference: DED Manufacturing of Large Critical Components: Pushing Boundaries of Metal Additive Manufacturing (AM)

Event Time

Originally Aired - Wednesday, September 14 11:00 AM - 11:55 AM Central

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Event Location

Location: McCormick Place, West Building - W192-C

Event Information

Title: IMTS Conference: DED Manufacturing of Large Critical Components: Pushing Boundaries of Metal Additive Manufacturing (AM)


This presentation will focus on large metal part additive manufacturing with a newly developed multi-nozzle DED manufacturing technology. Recent advances in the technology that now make large part printing economically feasible and technically superior will be highlighted. The presentation will showcase the additive manufacturing of NASA’s RS-25 engine nozzle liner. This particular part is 111” tall, has a 96” base diameter and weighs about 4100 Lbs. The build approach of this liner will be discussed to highlight various challenges to large part printing and strategies adopted to mitigate these challenges.

The goal of the presentation is to bring awareness to the industry about capability advancement of metal AM. This will be achieved by demonstrating the ability to print large complex parts with difficult materials while targeting critical industry applications. At the same time, the presentation is aimed to educate the attendees of the various challenges presented by such largescale printing, and how industry partners are working together to solve these difficult problems. Last but not the least, another important aspect of this presentation is to show how various industry teams came together with government agencies to advance existing technologies, as well as develop new ones, to solve difficult manufacturing challenges and advance metal AM to a new level of manufacturing.

As Additive Manufacturing (AM) is emerging as a main stream manufacturing technology, demand for large scale 3D printing is getting stronger. Directed Energy Deposition (DED) technologies offer particular benefit over more popular Powder Bed Fusion (PBF) technologies in that DED technologies are easily scalable. Direct Metal Deposition (DMD) is a DED technology based on laser and powder metal application using a closed-loop-feedback control system. 

This presentation will give a general industry overview of large part additive manufacturing and pivot on to the recent advances in DMD technology that is making large part 3D printing a reality. Particular focus will be on DM3D’s new Multi-nozzle System that is capable of printing parts up to 10ft in diameter, 10ft in height and 5,000 Lbs in weight. This multi-nozzle system doubles the part throughput with a further possibility of quadrupling it. Recent advances in DMD technology related to process monitoring, controlling and data acquiring, all of which are critical to successful build-up and qualification of large components, will be discussed. Microstructures and properties of some DMD processed materials will be demonstrated. Finally, case studies, involving real-life application of DMD technology within the space industry, will be demonstrated as examples of largescale AM; and the benefits of printing such parts will be highlighted. These studies will include DM3D’s recent work with NASA in developing large scale 3D printing for rocket engine components, such as RS-25 engine nozzle liner with particular dimensions up to 111” tall and 96” in diameter. The presentation will include a discussion on various challenges to printing such large parts, such as residual stress and distortion, quality control and inspection. Strategies to mitigate these challenges, including thermal-stress-distortion simulation, toolpath strategy and inspection techniques, will be discussed. It is important to note that the AM of this large difficult part has been made possible by the cooperation of a team of industry partners and government agencies working together to solve difficult problems which ultimately made the project a success. Therefore, this project is a memento to inter-industry collaboration.