ExafuseMetal additive manufacturing
Proof and retrieval layer

Connect the claim to a proof story, technical answer, FAQ block or research context before sending project data.

Research & projects

Research projects and development topics that support industrial laser metal deposition.

This section covers publicly funded projects, collaborative research and development themes without publishing confidential project data.

LMD process monitoring and melt-pool signal view

Publicly funded / collaborative project

BreitbahnDED: wider LMD tracks with rotating multispot optics.

BreitbahnDED is a cooperative research project for system and process development in Laser Metal Deposition, DED-LB/M and laser cladding. The project investigates rotating multispot optics so wider and more uniform weld beads can be generated without simply increasing laser focus and power.

Research problemConventional LMD tracks are often narrow, so large surfaces and high-volume builds require many overlapping paths.
Research directionRotating multispot optics, dynamic powder feeding and sensor-supported control are investigated together.
Project targetsPublic project communication describes initial 5 mm tracks, a potential path toward 10 mm, and productivity gains as research goals.
Industrial relevanceWider tracks matter for large-area deposition, repair, coating and near-net-shape build-up where fine powder-bed detail is not the main value.

Publicly funded research project

EIS-KW: additive manufacturing for temperature-controlled forging tools.

EIS-KW connects forging-tool requirements, cooling and heat-management concepts, material selection, additive manufacturing and wear evaluation. The project belongs on the research page because it shows how Exafuse links SLM / LPBF, LMD, hybrid route thinking and validation planning to a demanding tooling application.

Research problemForging tools face high thermal and mechanical loads, so temperature control, wear behavior and surface condition matter together.
Research directionEvaluate cooling concepts, tool materials, additive manufacturing routes, hardware integration and quality-management logic.
Exafuse roleSupport feasibility review, manufacturing concept development, sample-tool integration and tool-wear evaluation from an additive manufacturing perspective.
Industrial relevanceUseful for tooling teams exploring SLM, LMD or hybrid approaches for higher-load forging-tool concepts.

Project library structure

Separate public projects from internal development themes.

Publicly funded work is presented as project proof. Internal R&D is presented as capability direction and technical depth without exposing controlled research data.

Process selection route for LMD, SLM and hybrid manufacturing decisions

Public funded projects

BreitbahnDED, EIS-KW and future public or collaborative projects belong here with project goals, funding context, partner-proof references and approved media.

Open related page
 Laser Metal Deposition process adding metal to a component

Internal R&D themes

Process monitoring, geometry sensing, functionally graded materials and validation workflows can be shown as development directions, not guaranteed customer results.

Open related page
 Laser Metal Deposition process adding metal to a component

Industrial pilot topics

Customer-safe pilot stories can be added when the part class, goal, evidence and publication permission are clear.

Open related page
6-axis robotic LMD system for complex geometry, repair and cladding
LMD process monitoring and melt-pool signal view TRUMPF TruPrint 3000 SLM machine for compact detailed metal additive manufacturing

What research makes visible

A technical story buyers can understand without hype.

Research participation shows Exafuse working on process questions that affect cost, consistency and scalability in industrial metal additive manufacturing.

BreitbahnDED research process visual

Wide-bead LMD and DED

Wider deposition tracks can reduce the number of paths needed for large surfaces, but they also increase the need for controlled heat fields, geometry and bead-shape monitoring.

Open related page
 LMD process monitoring and melt-pool signal view

Sensor-supported monitoring

The research story includes CMOS cameras, pyrometers and triangulation sensors as tools for more transparent process observation and control development.

Open related page
 Inspection equipment for additive manufacturing quality review

Industrial validation

Research value is created when the method is tested against real material, geometry, finishing and inspection requirements rather than only small demonstrations.

Open related page

Exafuse role

Translate research into useful industrial process routes.

For buyers, Exafuse positions research as a practical bridge: part requirements, process integration, validation strategy and pilot feasibility.

Application requirementsIdentify industrial part classes where wider deposition, large-area coating or local build-up can create measurable value.
Process integrationConnect deposition hardware, powder delivery, optics, monitoring and post-processing into a realistic workflow.
Inspection equipment for additive manufacturing quality review
Validation route Evaluate geometry, material behavior, surface condition and inspection evidence before presenting claims externally. Open related page

Research themes

Research supports practical project decisions.

These themes can support technical articles, case studies and project discussions without publishing confidential research data.

BreitbahnDEDWide-bead deposition, productivity, multispot optics and large-surface relevance.
EIS-KWForging-tool research, cooling concepts, temperature control, additive tooling and wear evaluation.
Process monitoringMelt-pool behavior, powder delivery, temperature and geometry signals for better process understanding.
Laser Metal Deposition process adding metal to a component
Functionally graded materials Multi-material or graded structures as a feasibility topic, not a blanket production claim. Open related page
LMD, SLM, hybridProcess-selection logic for scale, fine detail, finishing, validation and cost.
Read the BreitbahnDED article Open EIS-KW project page Compare LMD, SLM and hybrid

Research articles

Exafuse R&D topics translated into customer-ready guidance.

These pages explain monitoring, AI-assisted control and neural-network image processing without exposing confidential model data, process parameters or customer results.

LMD process monitoring and melt-pool signal view
A35

Article

Melt-Pool Monitoring in Laser Metal Deposition: What Process Images Can and Cannot Prove

Melt-pool monitoring gives earlier visibility into LMD process behavior, but it is not a standalone quality certificate. It supports process understanding when image signals are connected to...

QualificationMetal AM routeDfAM and OEM
LMD process monitoring and melt-pool signal view
A36

Article

AI in Laser Metal Deposition Process Control: From Decision Support to Closed-Loop Claims

AI can support LMD process control when model outputs are tied to validated signals, clear action limits and inspection evidence. The important distinction is between decision support, param...

QualificationMetal AM routeDfAM and OEM
LMD process monitoring and melt-pool signal view
A37

Article

Image Processing with Neural Networks in LMD: Where Pix2Pix-Style Models Fit

Pix2Pix-style neural networks can support LMD image-processing research by translating process images into more useful visual representations, but generated outputs must be validated against...

QualificationDfAM and OEMMetal AM route
Valve seat ring after dye test with no visible cracks or pores in the photographed condition
A38

Article

Crack-Risk Control for Hard Co-Based LMD Coatings on Ring Geometries

Hard Co-based LMD coatings on ring geometries need more than a powder selection. Geometry, preheating, layer strategy, powder-feed direction, travel-speed review and dye inspection decide wh...

Wear and corrosionQualificationRFQ and buying

Recommended next steps

Continue with the most relevant Exafuse path.

Move from the current topic into the closest service, proof page, technical article, FAQ or feasibility request.

Research to process

Move from BreitbahnDED into LMD productivity, monitoring and quality evidence.

ArticleA21: Research Spotlight: BreitBahnDED and Why Wider Beads Matter for Industrial ProductivityCase studyCS15: Duisburg Bridge Components with LMD: 750 kg+ Nodes and Handrails from CAD to Validated ProductionArticleA32: Large Structural LMD for Bridge Components: Lessons from the Duisburg Bridge ProjectArticleA06: LMD for Large Metal Parts: Bead Width, Deposition Efficiency, and ProductivityArticleA12: Monitoring and Control in DED/LMD: What In-Process Signals Mean for QualityPageMachine capabilitiesPageQuality

Metal AM

Request a process-selection feasibility review

Send CAD, material, approximate size and target finish. Exafuse can review whether LMD, SLM or a hybrid route is the practical process path.

Start manufacturing RFQ

Research to pilot

Route OEM, R&D and product teams into a controlled feasibility discussion.

ArticleA15: Functionally Graded Materials with DED/LMD: When a Gradient Outperforms a Single AlloyCase studyCS15: Duisburg Bridge Components with LMD: 750 kg+ Nodes and Handrails from CAD to Validated ProductionArticleA32: Large Structural LMD for Bridge Components: Lessons from the Duisburg Bridge ProjectResearch noteCS11: Research Topic: Functionally Graded LMD Pipe with Material TransitionFAQFAQ07: DfAM for Industrial Metal Parts FAQ: Geometry, Tolerance, and Post-MachiningPageMetal AM: LMD & SLMPageFeasibility request

Metal AM

Request a process-selection feasibility review

Send CAD, material, approximate size and target finish. Exafuse can review whether LMD, SLM or a hybrid route is the practical process path.

Start manufacturing RFQ

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