Modeling and Simulation Studies of Titanium Parts Using Multi-axis Laser DED Manufacturing

Multi-axis with Directed Energy Deposition (DED) in additive manufacturing is a powerful tool for building parts that traditional three-axis printing cannot achieve. Direct Metal Deposition (DMD®), which is a form of DED technology, utilizes a high-power laser and metal powders along with a closed-loop feedback system. Multi-axis in combination with DMD, gives the capability to build large-scale parts with more aggressive curvatures and higher complexities. This eliminates the need for supports which both reduces cost and lead times for printing. This can also be a benefit for multi-material printing, allowing inside or outside coatings of parts to help with things like rigidity, corrosion, or wear. Large scale parts that need multi-setup printing can have stress and distortion challenges. This is due to the high heat input from the print laser. Using modeling and simulation tools these challenges can be mitigated.

This presentation will highlight the rationale behind the process of decomposing 3D-printed parts for multi axis buildup. It will also cover strategies for tool pathing and positioning parts for the deposition process and the limitations based on machine and axis capabilities.

There will be a case study of titanium housing to illustrate the decomposition method for 3D printing parts with multi-axis and how simulation tools can help predict distortion and offer compensation tools to ensure dimensional accuracy. Examples of the various applications of multi-axis 3D printing, including fuel tanks, rocket grid fins, and more will be discussed to highlight the applicable use cases and future work that can be done to advance large format DED printing.