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Laser Metal Manufacturing Guide

The laser-engineered net shaping (LENSTM) process uses a laser to additively manufacture metal parts directly from CAD files in a layer-by-layer manner. Powder metal particles are delivered via gas into a molten pool formed by an Nd:YAG laser. The part is built up from the bottom to top by depositing successive layers with different scan directions to improve strength. The LENSTM process can produce functional metal prototypes, repairs, and low-volume production parts in materials like stainless steel, titanium, and super alloys.

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230 views2 pages

Laser Metal Manufacturing Guide

The laser-engineered net shaping (LENSTM) process uses a laser to additively manufacture metal parts directly from CAD files in a layer-by-layer manner. Powder metal particles are delivered via gas into a molten pool formed by an Nd:YAG laser. The part is built up from the bottom to top by depositing successive layers with different scan directions to improve strength. The LENSTM process can produce functional metal prototypes, repairs, and low-volume production parts in materials like stainless steel, titanium, and super alloys.

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Devadatt
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M .Tech.

CIM LENS 2018

LASER ENGINEERED NET SHAPING

The laser-engineered net shaping (LENSTM) process is a laser-assisted, direct metal


manufacturing process by Sandia National Laboratories. The process incorporates features from
stereolithography and laser surfacing, using computer-aided design file cross sections to control
the forming process. Powder-metal particles (less than 150 µm) are delivered in a gas stream
into the focus of a Nd YAG laser to form a molten pool. The part is then driven on an x/y stage
to generate a three-dimensional part by layer-wise, additive processing.

The process begins with a CAD solid model of the component in the familiar .STL file format.
LENS-specific software then converts the CAD information into a series of toolpaths and
control sequences to produce a deposition path. This information then guides the system to
deposit successive layers of material, building the part from bottom to top. To provide the best
build, each successive layer is deposited in a scan direction that is different from the previous
layer to improve the material strength. As each successive layer is deposited, the powder
delivery nozzle, together with the laser focus plane, moves vertically upward away from the
build. This process produces functional metal components directly from CAD solid models.
Applications include fabrication of functional prototypes, repair and overhaul and low-volume
production. The process has the ability to produce components in a wide variety of metals,
including stainless steel, tool steels, aerospace super-alloys, copper, aluminum and titanium. The
low-volume production application is particularly attractive in producing parts from titanium,

Prof. Devadath V R P E S C E Mandya 1


M .Tech. CIM LENS 2018

due to the difficulty in working titanium in alternative processes and the excellent material
properties achieved

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Prof. Devadath V R P E S C E Mandya 2

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