Laser Deposition Technology (LDT)

Laser Freeform Manufacturing Technology (LFMT)

Laser Freeform Manufacturing Technology (LFMT) is used to deposit "freeforms" of near-net-shape metal components, which are nearly 100% dense with mechanical properties comparable to wrought materials, directly from processed CAD files. Freeforms may be thin wall (minimum 0.060 in. thick) or solid builds to any thickness.

First a CAD file of the desired part must be provided. Next this file is modified and processed by the system software where the tool path for the laser is generated. A target plate is required as a base to start the build. The target plate may be incorporated into the final part or may simply be removed when the freeform build is complete. Thermal treatments and CMM scans of the completed freeform builds may be required depending on the specific application. The largest freeforms deposited to date weigh in at more than 100 pounds.

LFMT has many applications.  LFMT can manufacture components with high aspect ratio features such as structural components for aircraft bulk heads or spars. The figures below show a variety of LFMT thin wall freeforms. Special pipes, creative hollow shapes, and hollow stem engine valves are just a few examples of the wide open potential applications for this capability.

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Sample Freeform Parts Freeform Part Being Built By Laser Sample Freeform Part Sample Freeform Part Sample Freeform Part

Case Study: Ti-6Al-4V Laser Freeform For SDSM&T Formula SAE Team

RPM and Associates built an upright to be used for a Formula SAE racing car for the South Dakota School of Mines and Technology racing team. The part was designed and delivered as a CAD drawing file. The drawing file was converted to a machine tool path file that was used to build the part using our Laser Freeform Manufacturing Technology (LFMT).

Laser Deposition Process	Laser freeform manufacturing of Ti-6Al-4V Uprights for South Dakota School of Mines and Technology Formula SAE Team.
Laser Deposition Process	Upright After Laser Deposit	Upright Installed

Case Study: Ti-6Al-4V Ribbed Brackets

Ti-6AI-4V Ribbed Bracket With Cross Hatching Material Laser Power (watts) Inch^3/hr. lbs./hr. Efficiency Ti-6AI-4V 3000 9.77 1.56 59%
Ti-6AI-4V Small Ribbed Bracket With Contour Only Material Laser Power (watts) Inch^3/hr. lbs./hr. Efficiency Ti-6AI-4V 3000 12.25 1.96 78%

About RPM and Associates

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Our highly skilled team of mechanical, metallurgical, electrical, and software engineers will analyze your problem and provide a timely solution.

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