Formalloy’s X-Series Laser Metal Deposition System (Courtesy Formalloy)

Formalloy, headquartered in San Diego, California, USA, has showcased its award-winning Directed Energy Deposition (DED) systems, including robotic integration and its latest Alloy Development Feeder (ADF), at RAPID + TCT 2019, in Detroit, Michigan, USA, from May 20–23.

The company’s DED systems feature the Formalloy AX Metal Deposition Head and a customisable build volume, with up to five-axes of motion. Formalloy states that the AX head has proven reliability for up to 8kW laser power and built-in quick-release features allowing for rapid maintenance and component swaps in less than three minutes.

Regarding the release of its Alloy Development Feeder, Formalloy states that the system enables high throughput bulk alloy synthesis for the development of new materials and alloys. Material development expert, Dr. Kenneth Vecchio, a Professor at the University of California San Diego, stated, “The ADF provides an unprecedented capability for material development and research.”

According to Formalloy, the need for new alloys optimised for Additive Manufacturing is not only evident by researchers and materials companies, but for end users also. In particular, end users of AM in the aerospace and automotive industries are investing in new materials that feature superior properties to traditional materials.

The company states that in addition to new alloy development, the ADF enables precise deposition of gradient materials as each layer is pre-alloyed to ensure composition accuracy for detailed gradient strategies that are not achievable with other processes. Gradient parts can reportedly provide enhanced material properties and simplification of multiple-part assemblies made of various metals into a single part.

As an alternative to purchasing a turn-key metal deposition system, a robot can be integrated with the Formalloy AX deposition head, ADF or PF powder feeders, and a laser to additively manufacture, clad, and repair metal parts.