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What is Directed Energy Deposition in 3D Printing
Directed Energy Deposition (DED) is a term that encompasses technologies involving semi-automated powder spraying and wire welding for manufacturing. When applied to 3D shapes, DED is considered an additive manufacturing process. It typically results in a rougher surface compared to Powder Bed Fusion, due to the larger bead sizes and coarser powder used, which often necessitates additional machining.
DED systems generally fall into two categories: deposition systems and hybrid systems that combine a DED head with traditional machining equipment. The main advantages of DED include faster deposition compared to powder bed fusion 3D printing and the ability to create functionally graded material structures, especially when using powder. Additionally, since the feedstock and energy source move together, DED systems can manufacture very large structures, unrestricted by the size limitations of a build box. In some cases, DED can be more effective than traditional manufacturing methods or powder bed fusion.
Most DED systems consist of a deposition head that uses either wire or powder and is mounted on a robot or CNC system. Common energy sources include Arc, Laser, or Electron Beam, with lasers being the most frequently used for powder feedstock. The process involves offline programming to generate a tool path from a sliced CAD file. The motion system then follows this path, depositing material in layers to build the desired shape. DED is compatible with a variety of weldable alloys, such as aluminum, steel, nickel, and titanium. Depending on the chosen alloy and process, shielding gas may be applied locally or within an enclosed environment.
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