Invention Reference Number
This technology provides a reliable method for determining the standoff distance in Laser Powder Directed Energy Deposition (LP-DED) systems. Standoff distance—the space between the deposition nozzle and build surface—is critical for ensuring consistent part quality and efficiency. Current monitoring methods are costly, intrusive, or slow. This invention offers a real-time, cost-effective solution that maintains build speed while improving part accuracy and reducing defects. The approach enhances both process efficiency and product reliability, supporting broader adoption of advanced additive manufacturing.
Description
Additive manufacturing processes such as LP-DED rely on precisely controlled conditions to achieve high-quality parts. A key factor is the standoff distance, which directly impacts powder capture efficiency, energy distribution, and final part geometry. Conventional methods for monitoring this distance are often expensive, restricted by build geometry, or introduce delays in the process. This invention introduces a non-intrusive system capable of continuously predicting standoff distance during deposition without disrupting production. The system integrates multiple sensing approaches to provide real-time monitoring that adapts to diverse geometries and deposition conditions. By maintaining the optimal standoff distance, the invention reduces variability, prevents over- or under-building, and enhances the structural integrity of manufactured parts. This method enables more efficient builds, lowers production costs, and improves material utilization, offering a practical pathway for manufacturers to scale LP-DED processes more effectively.
Benefits
- Real-time monitoring of critical build parameter
- Improved layer uniformity and part quality
- Reduced production time and costs
- Non-intrusive and adaptable to complex geometries
Applications and Industries
- Additive manufacturing equipment developers
- Aerospace, defense, and automotive part production
- Industrial tooling and repair applications
- Metal fabrication and advanced materials processing
Contact
To learn more about this technology, email partnerships@ornl.gov or call 865-574-1051.
