Setup for Directed Energy Deposition 340

3D print file

A collection of data about an object that may include its dimensions, color, material, and other data that is read by machine software. 3D print files can include STL files, which represent an object as interconnected triangles, and AMF files, which represent dimensions, colors, and materials.

3D scanning

Capturing the geometric surface data of an object using a combination of light and sensors. 3D optical scanning collects data to be turned into digital 3D models.

additive manufacturing

AM. The process of joining or solidifying materials to make an object from a three-dimensional computer model. Additive manufacturing methods typically build up layers of material to create an object.

aluminum

A silver-white, lightweight metal that resists corrosion and is a good conductor of electrical and thermal energy. Aluminum is sometimes used as build material in additive manufacturing.

AM

Additive manufacturing. The process of joining or solidifying materials to make an object from a three-dimensional computer model. Additive manufacturing methods typically build up layers of material to create an object.

AMF file

Additive Manufacturing File. A file format for use in additive manufacturing that contains data for colors, materials, and other part features. The AMF format allows for more complex shapes than the standard STL format, including curved triangles.

band saw

A cutting device that uses a serrated blade constructed from a continuous loop or band of metal. Band saws are used in additive manufacturing post-processing to remove metal parts from build plates.

build plate

A removable flat surface on which an additively manufactured part is constructed. Build plates are removable build platforms and must be carefully centered and leveled to ensure a successful build.

carrier gas

An inert gas in a DED system used to deliver powdered material to the melt pool. Carrier gas flow is related to the deposition rate.

ceramic

A hard, brittle material that can withstand high temperatures and resist corrosion. Ceramics, which include metal oxides, nitrides, and glasses, are sometimes used as build material in additive manufacturing.

chemical hazards

A substance or mixture of substances that is harmful to employees. Chemical hazards include substances in the form of liquids, vapors, fibers, or dust.

clamps

A device that holds an object by applying downward or inward pressure. Clamps are often used as workholding devices in manufacturing.

CNC mill

A machine that uses computer numerical data to control cutting operations on flat, square, or rectangular workpieces. CNC mills can perform milling, drilling, boring, or other subtractive manufacturing processes and can also use DED nozzles in hybrid applications.

combustible

A material that can quickly catch fire if it comes in contact with sparks or fire. Combustible materials require special storage and labeling.

composites

A group of materials that are made by mixing together two or more of the following groups: metals, plastics, and ceramics. Composites are sometimes used as build material in some additive manufacturing methods, such as material extrusion and directed energy deposition.

Computer numerical control

CNC. A programmable system of software and hardware that directs the operation of a machine. Computer numerical control systems use mathematical data to direct machine movements.

computer-aided design

CAD. Computer software used to create a three-dimensional (3D) model of a part before it goes into prototyping or production. Computer-aided design models are converted to an STL format then to a build file for use by additive manufacturing (AM) machines.

consumable electrode

An electrode used in DED that conducts electricity to the arc and also melts into the melt pool to form the part. Some consumable electrodes also provide shielding that protects the arc and melt pool.

DED

Directed energy deposition. An additive manufacturing process in which focused thermal energy is used to melt materials as they are deposited. DED is often used with powdered or wire metal feedstock.

deposition head

A DED machine component that includes the energy source and dispensing nozzle. Deposition heads are used in laser metal deposition (DED) processes.

deposition rate

The rate at which material is layered in an additive manufacturing process. Deposition rate helps determine the rate at which a part is built.

directed energy deposition

DED. An additive manufacturing process that uses focused thermal energy to melt materials as they are deposited. Directed energy deposition is often used with powdered or wire feedstock.

drill press

A machine tool that is used for a range of holemaking operations such as drilling, reaming, and tapping. A drill press is limited to only vertical motion of the spindle in order to feed the cutting tool into the workpiece.

drills

A multi-point cutting tool used to create a round hole in a workpiece surface. Drills are common tools for holemaking operations on CNC machines.

EBFF

Electron beam freeform fabrication. An additive manufacturing technology developed by NASA that uses an electron beam and metal wire feedstock to build and repair parts. EBFF, sometimes referred to as EBF3, uses an electron beam and metal wire feedstock.

electric arc

The area in which electricity jumps from an electrode to a conductor to produce extreme heat and light. Electric arcs are used in thermal welding and cutting applications, as well as in directed energy deposition.

electric shock

The flow of electricity through the body. Severe electric shock can be fatal.

electron beam

A narrow stream of electrons that create focused thermal energy. Electron beams are used in some additive manufacturing processes to fuse materials.

electron beam freeform fabrication

EBFF. An additive manufacturing technology developed by NASA that uses an electron beam and metal wire feedstock to build and repair parts. Electron beam freeform fabrication, sometimes referred to as EBF3, uses an electron beam and metal wire feedstock.

end effectors

A device attached to the end of a robot arm in order to interact with a part, component, or material. An end effector, also known as an end of arm tool, may be a gripper, drill, arc welding torch, deposition head, or other tool.

end mills

A milling cutter that cuts with its bottom and side edges. End mills can be used to machine grooves, slots, circular slots, and pockets, among other features.

energy source

The component on a DED machine that melts the material to form the part. DED energy sources include lasers, wire arcs, and electron beams.

environmental controls

The equipment designed to clean or control the environment surrounding a manufacturing operation. Environmental controls can include filtration systems, ventilation systems, temperature controls, or other settings.

feed system

The method or mechanism that delivers material to the part build. DED machine feed systems include powder feed and wire feed systems.

feedstock

The raw material that is used to make manufactured parts. Feedstock for additive manufacturing methods includes filaments, pellets, wire, and powder.

fiber laser

A type of laser that creates an intence beam of light using a fiber optic cable and rare-earth minerals. Fiber lasers are solid-state lasers typically used in directed energy deposition.

fixtures

A customized workholding device that is designed to effectively support, locate, and hold a specific type of workpiece. Workpieces with multiple complex dimensions often require dedicated fixtures.

G code

A method of programming that pairs address letters with numerical values to form words. G code programs are used to direct machine movements in additive manufacturing, CNC machining, and hybrid machining.

grinding

A machining process in which an abrasive is used to precisely cut and shape the surface of a workpiece. Grinding operations are often used to remove small amounts of material from a workpiece and create good surface finish.

Hazard Communication Standard

HCS. An established OSHA policy that sets guidelines for hazard communication. The Hazard Communication Standard emphasizes labeling, Safety Data Sheets, and training and is aligned with the Globally Harmonized System.

hazards

Anything that can cause injury, illness, or death. Hazards are broken down into chemical, biological, physical, and ergonomic categories.

heat treatment

A controlled heating and cooling process used to change the structure of a material and alter its physical and mechanical properties. Heat treatment is often used to improve the hardness and durability of an additively manufactured part.

HMI

Human-machine interface. A device connected to a machine that allows operators to monitor and control a machine or process. An HMI may have a touch screen or control pad.

holemaking

A machining operation in which a single- or multi-point cutting tool creates, sizes, or finishes a hole. Holemaking includes drilling, boring, reaming, and tapping.

human-machine interface

HMI. A device connected to a machine that allows operators to monitor and control a machine or process. A human-machine interface may have a touch screen or control pad.

hybrid manufacturing

A manufacturing approach that produces parts by combining multiple manufacturing processes in a single digital workflow or on a single machine. Hybrid manufacturing may describe a variety of manufacturing processes combinations but is most often associated with combining additive and subtractive processes.

Inconel

A superalloy based in nickel and chromium that is designed to perform well in extreme environments. Inconel resists both oxidation and corrosion.

inert

A gas or other substance that does not chemically react with the substance it contacts. Inert gases include nitrogen, helium, and argon.

laser

An intense beam of light that can be precisely aimed and controlled. Lasers are sometimes used to selectively solidify or fuse materials in additive manufacturing methods, including directed energy deposition, powder bed fusion, and vat photopolymerization.

laser cutting

A thermal cutting process that uses a focused beam of coherent, collimated, monochromatic light to sever a workpiece. Laser beam cutting is usually an automated process that produces intricate and repeatable cuts.

laser metal deposition

LMD. A DED process that uses a laser beam to melt powdered metal feedstock into a part. Laser metal deposition, often called laser engineered net shaping (LENS), can create parts from specialized alloys and other materials.

laser power

The amount of energy that is used to produce the laser beam on a DED machine. Laser power settings affect print quality.

LMD

Laser metal deposition. A DED process that uses a laser beam to melt powdered metal feedstock into a part. LMD can create parts from specialized alloys and other materials.

locating

Establishing a workpiece in a set position. Locating a workpiece correctly ensures that it will be manufactured to the correct specifications and tolerance.

machining

A manufacturing process that involves removing material to form an object. Machining can occur using traditional methods, like turning, drilling, milling, and grinding, or with less traditional methods that use electricity, heat, or chemical reaction.

material hoppers

A container used to hold raw materials for use in an industrial process. Material hoppers used in metal AM processes hold powdered metal.

melt pool

An area of liquefied material, usually metal. Melt pools are created in directed energy deposition (DED) to fuse powdered metal or metal wire in layers to form a solid part.

melting point

The temperature at which a material changes from a solid to a liquid. Melting point varies based on the properties of the material.

metal alloys

A metal consisting of a mix of two or more elements, one of which must be a metal. Alloys include cast iron and different types of steels.

metals

A naturally occurring material with high strength, hardness, and electrical and thermal conductivity. Metals are categorized as either ferrous or nonferrous.

milling

A cutting operation in which a rotating multi-point cutting tool is fed along a part's surface to remove material. Milling operations are very versatile and generally produce flat surfaces.

National Fire Protection Association

NFPA. A non-profit organization that maintains standards of public safety and fire prevention. The National Fire Protection Association developed NFPA 652, the Fundamentals of Combustible Dust Standard.

near-net shape

A part with dimensions that are close to its final specified form after initial manufacturing steps. Near-net shape parts require little subsequent machining.

NFPA 652

The Fundamentals of Combustible Dust Standard developed by the National Fire Protection Association to prevent fires and explosions associated with combustible dust materials. NFPA 652 applies to powdered materials used in DED.

nitrile gloves

A low-cost, copolymer glove that protects against various chemicals. Nitrile gloves are highly puncture resistant compared to latex.

nozzle

The component on a DED machine that dispenses the material. DED nozzles dispense either powder or wire feedstock.

Occupational Safety and Health Administration

OSHA. A government agency dedicated to reducing injuries, illnesses, and deaths in the workplace. The Occupational Safety and Health Administration sets standards to maintain accident-free workplaces.

offsets

A numerical value stored in the CNC control that repositions machine components. Offsets are used to adjust for differences in tool geometry, part size, tool wear, and any other changing variables that may affect the manufacture of the part.

part adhesion

The measure of bond strength between a substrate material and a build material formed by a melt pool. Part adhesion depends on the compatibility of the substrate and build materials.

part geometry

The linear and curved shapes that characterize a part. Complex part geometry is one of the key advantages of multi-axis DED.

part zero

The starting point of X, Y, and Z coordinates for a specific workpiece. Part zero acts as a reference point for all part dimensions.

personal protective equipment

PPE. An article of clothing or a device worn to minimize exposure to hazards and prevent injury. Personal protective equipment may include safety glasses, safety gloves, ear plugs, respirators, or steel-toed boots.

plasma arc

A stream of plasma created by heating a shielding gas with an electric arc. A plasma arc is used to melt material feedstock in plasma wire arc additive manufacturing.

plasma wire arc additive manufacturing

Plasma WAAM. A DED process that uses a plasma arc, sheilding gas, and non-consumable electrode to melt materials into a part. Plasma wire arc additive manufacturing often uses powder feedstock but may also be designed for wire feedstock.

post-processing

A procedure used to clean, improve, or otherwise finish a part after it has been manufactured. Post-processing procedures include abrasive finishing, heat treatment, and painting.

powder feed system

A machine or component that delivers powdered material feedstock. Powder feed systems may need to be filled or exchanged when setting up for DED.

powdered metal

A metallic powder that is often used as a build material in additive manufacturing (AM). Powdered metal is stored in a material hopper and deposited through a nozzle or print head to build a part layer by layer in AM applications.

PPE

Personal protective equipment. An article of clothing or a device worn to minimize exposure to hazards and prevent injury. PPE may include safety glasses, safety gloves, ear plugs, respirators, or steel-toed boots.

print resolution

The fineness of detail in a computer-aided design (CAD) model that determines the accuracy of a printed part. Print resolution helps determine the part's surface finish quality, with greater resolution leading to better surface finish.

print speed

The rate at which a DED print head or worktable moves moves in a linear or rotational axis while printing. Print speed is typically measured in millimeters per second (mm/s).

probing systems

Equipment installed on a machine that can be calibrated to determine and enter offset values automatically. Probing systems may use wireless or laser technology to detect the position of CNC tools and other components.

respirators

A breathing device worn to prevent inhalation of hazardous substances. Respirators may purify air or supply air for the wearer.

respiratory hazards

An airborne substance that can cause physical harm if someone breathes it in. Respiratory hazards include harmful gases, dust, fumes, mist, smoke, and vapors.

robotic arm

A programmable or remote-controlled device that simulates the movement of a human arm. Robotic arms are used in a variety of assembly and manufacturing applications, including DED.

Safety Data Sheet

SDS. Mandatory information that must accompany almost every chemical in the workplace. A Safety Data Sheet includes details such as the hazards, precautions, and first-aid procedures associated with the chemical.

shielding gas

A gas that protects the melt pool and energy source from atmospheric contamination. Shielding gas is supplied by a cylinder and flows through welding torch or deposition head on a DED machine.

simulation

A computer re-creation of a physical space and activity. Simulations allow DED machine operators to walk a part program through a computerized version of the manufacturing process.

slicer

A computer program that divides an STL file into layers for additive manufacturing (AM). Slicers can either be separate computer programs or part of the machine interface.

stainless steels

A grouping of steels that contain large percentages of chromium, as well as nickel, manganese, and/or nitrogen. Stainless steels have very high hardness and corrosion resistance.

STL file

A file that represents a 3D model as a series of interconnected trianges. STL files must be converted to build files so that they can be used by additive manufacturing (AM) machines.

substrate

A surface or medium that serves as a base for other materials or components. The substrate on a DED machine is the removable build plate.

subtractive manufacturing

Any manufacturing process in which a piece of raw material is machined into a desired final shape through a controlled material removal process. Subtractive manufacturing methods are fast but create a large amount of waste.

test coupons

A sample part or piece of material made for the purpose of testing and inspection. Test coupons have exactly the same variables, such as necessary resolution, as outlined in the specification for the final part.

thermal conductivity

A material's ability to conduct heat. Thermal conductivity depends on the material's structure and temperature.

three-dimensional

3D. Having height, width, and depth. Three-dimensional parts are created during additive manufacturing (AM) processes.

titanium

A metal that has a high strength-to-weight ratio and corrosion resistance. Titanium is often used in aerospace and biomechanical applications.

toolpaths

The series of coordinate positions that determine the movement of a tool during a manufacturing operation. Toolpaths for additive manufacturing machines are automatically generated by specialized slicing computer programs that analyze the 3D part model and divide it into layers.

ultraviolet radiation

UV radiation. The energy emitted by light sources with wavelengths slightly smaller than violet light. Ultraviolet radiation, which cannot be seen with the human eye, can lead to serious skin and eye issues with prolonged exposure.

vacuum sealed chamber

A sealed enclosure from which air is removed by a vacuum pump. Vacuum chambers surround the entire build area in some DED systems.

vises

A workholding device with two jaws that grip and hold a workpiece in place. Standard vises keep parts in a fixed position on the worktable.

WAAM

Wire arc additive manufacturing. A directed energy deposition (DED) process that uses an electric arc and a shielding gas to melt materials as they are deposited onto a build plate. WAAM uses wire feedstock.

waypoint

An intermediate point in a path between a robot's source and target positions. Waypoints, also known as via points, determine the shape and route of a robot's path.

weld puddle

The small area of molten metal that forms during welding. The cooled weld puddle forms the permanent joint.

welding

The joining of two or more materials, usually metals, using heat, pressure, or a combination of energy sources. Welding fuses materials together permanently.

wire arc additive manufacturing

WAAM. A directed energy deposition (DED) process in which metal wire feedstock is melted by an electric arc and deposited onto a substrate. Wire arc additive manufacturing is similar to welding and uses much of the same components.

wire electrical discharge machining

Wire EDM. A material removal process in which electricity is fed through a thin strip of metal to shape or separate parts. Wire electrical discharge machining is often used to accurately cut metal additive manufacturing parts from the build plate.

wire feed systems

A machine or component that delivers material feedstock in the form of a wire spool. Wire feed systems may need to be calibrated or changed when setting up for DED.

wire feeder

A device that delivers a supply of wire electrode to the melt pool. The wire feeder may be built inside the power source or be an external device set beside it.

workholding

A method or device for securing a workpiece. Workholding can include chucks, vises, and bolts.

workpiece

A part that is in the process of being manufactured. A workpiece may be a complete product by itself or one component of a product consisting of many parts.

worktable

The part of a DED machine that supports the workpiece. The worktable, or table, can move along a combination of linear and rotational axes, depending on the configuration of the machine.