Laser Metal Deposition (LMD)
Formalloy’s LMD Cladding technology is used to create wear and corrosion-resistant coatings that are 100% dense and metallurgically bonded to the substrate. The LMD cladding process inputs minimal heat to the part compared with PTA, TIG and MIG weld processes. LMD provides very low dilution between the coating and substrate and allows for fine deposit microstructures, precise control of the coating thickness and reduced distortion into the base part. For wear resistance, a variety of nickel, cobalt, and carbide-based powders can be used.
Formalloy’s additive manufacturing technology utilizes Laser Metal Deposition (LMD) to create metallic parts to near-net shape, increasing the design envelope while providing a more economical solution than producing the same part with conventional methods. Formalloy’s additive manufacturing systems enable reduced machining time and nearly eliminate material waste, particularly with high-value materials such as titanium and Inconel. 3D printing parts with Formalloy’s process can provide design features that can’t be achieved with conventional manufacturing methods, such as internal cooling channels and gradient material or multi-metal parts.
Unlike powder-bed technologies such as direct metal laser sintering (DMLS), Formalloy’s LMD process deposits metal with a coaxially aligned laser/powder nozzle. Our process typically achieves much faster build times, superior material properties and a much larger build envelope compared with powder-bed technologies.
Formalloy’s LMD process can produce parts with dimensions from less than 1 mm to greater than 1 meter with bead widths from 250 micron and up.
FormAlloy’s X & L-Series Directed Energy Deposition (DED) Systems
FormaAlloy’s X & L-Series laser metal deposition systems feature closed-loop control, variable-wavelength lasers, and Form feed powder feeders for gradient/bi-metallic structures.
Our X & L-Series systems boast improved quality, better powder efficiency, and the ability to print with the most comprehensive list of metal alloys on the market. Each machine comes standard with the FormAlloy AX metal deposition head and a customizable build volume with up to 5-axes of motion.
FormAlloy’s X & L-Series systems can be configured with Dynamic Layer Selection technology to monitor build quality and accuracy in real-time, auto-set layer thickness and auto-correct errors to achieve a part that is free of dimensional defects. The FormAlloy AX head has proven high powder efficiency and built in quick release features for ease of maintenance and component swaps. FormAlloy designs all components and systems to utilize open standards for powder supply, allowing the user to provide their own powders if desired. These systems provide a cost-effective solution for 3D metal part production, repair and cladding to a diverse set of industries.
|Specifications||X & L-Series|
|Build Volume||200x200x200mm | 500x500x500mm | 1x1x1m (Customizable also available)|
|Deposition Rates||Up to 7 kg/hr|
|# of Axes||Up to 5|
|# of FormAlloy AX Heads||Up to 2|
|FormAlloy AX Nozzle Type||Coaxial, 4-Stream|
|# of FormAlloy Feeders||Up to 4|
|# of Lasers||Up to 2|
|Laser Type||IR (970-1070nm), Blue (450 nm)|
|Laser Power||Up to 8 kW|
|Powder Efficiency||Up to 95%|
|Dust Removal/Extraction||< 5 micron filtration|
|Inert Gas Build Chamber (L-Series)||< 10 ppm oxygen content|
|Build Plate Heating||Optional|
|Dynamic Layer Selection||Optional|
|Melt Pool Temperature Monitoring||Optional|
|Optical Process Monitoring||Optional|
|Melt Pool Size Monitoring & Control||Optional|