New develpments in 3D laser additive manufacturing

Laser Additive Manufacturing (LAM) titanium powder consolidation has been practiced for a number of years. The LAM technology holds great promise for repair, direct fabrication and modification of titanium Alloy components. This technology also provides for surface modification through alloying and physical texturing. The LAM technology has been applied to the development of a number of aerospace applications through its ability to add almost any powder material to a surface of an existing sub-structure. However, this technology as been limited by its inability to function in true 3-D environments. The limitations have been the result of the inability to easily translate from solid models and program in parameter changes at selected points. This paper describes a new method that allows true three-dimensional fabrication to those applications where a high resolution and tolerances are important (e.g., knife edges, seal edges, optics fixtures). The new system, MicroLam (m-Lam), an adaptation of the flexible robotic environment (FRE) to LAM, is being developed to fabricate bio-medical devices under a contract (#W81XWH-08-1-0315) through the US Army Medical Command. The m-Lam employs a six axis coordinated motion system with a higher resolution (∼100 microns) than previously possible for other LAM systems. The general areas where this and the current LAM technologies will be directed includes but is not limited to: repair of complex structures: fabrication of additive shapes on existing structures; seal edges; leading edges; wear resistant surfaces containing a variety of conventional carbides, silicides, borides and novel nano-particle reinforcements; build up of functional material on wrought and cast structures; and functionally gradient transition layers.