DEDSmart® Advanced Manufacturing
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DEDSmart® Deposition Software for Directed Energy Deposition

Real-Time Data. Smarter Builds. Total Control.

DEDsmart® by FormAlloy delivers intelligent software and monitoring solutions for Directed Energy Deposition (DED) metal additive manufacturing. Record, analyze, and optimize builds for enhanced performance, quality, and repeatability—every time.

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+1 619 377 9101

Integrated with FormAlloy’s DED systems, DEDsmart® captures all build parameters and enables playback for repeatable processes. It’s real-time manufacturing intelligence, engineered for control and results.

DEDSMART® SOFTWARE SUITE for Directed Energy Deposition Monitoring

High-Performance DED Systems for Complex Metal Manufacturing

DEDsmart® is FormAlloy’s proprietary software platform designed to bring intelligence and precision to every layer of your additive manufacturing process. Optimized for Directed Energy Deposition, the software captures and stores comprehensive build parameter data to enable detailed post-build analysis for quality assurance, troubleshooting, and process validation. With the built-in playback function, users can freeze and repeat successful builds with consistency, enabling faster development cycles and repeatable success.

DEDsmart® captures build data for analysis, validation, and repeatability. Playback lets users repeat successful builds for consistent results and faster development in metal additive manufacturing.

Laser Power (W)

3D representation of a mechanical component color-mapped by power (W), showing areas of energy input from blue (300) to red (500) across the structure.

Feed Rate (MM/MIN)

3D printing | Directed Energy Deposition

PF Disc Speed (RPM)

3D model of a mechanical part color-mapped by disk speed (rpm), ranging from blue (0.5) to red (1.1), showing variation across surface layers.

Each unit is tested in real-world conditions, including high-heat and crash scenarios, ensuring operational resilience. With features like built-in sensors, smart powder management, and fast-change components, our hardware reduces maintenance and maximizes uptime for high-volume environments.

Each unit is tested in harsh conditions and includes sensors, smart powder control, and quick-swap parts to boost uptime and reduce maintenance.

INTEGRATED IN-PROCESS MONITORING & CONTROL

OPTICAL MELT POOL MONITORING

FormAlloy’s Optical Monitoring system delivers real-time, high-frame-rate video of the melt pool during the build process—up to 55 FPS. Operators gain off-axis live visibility to ensure quality mid-print, with video recordings available for post-process evaluation. This gives users both live diagnostics and historical data for quality assurance.

FormAlloy’s Optical Monitoring captures real-time melt pool video up to 55 FPS, giving operators live visibility and recorded playback for diagnostics and post-build quality analysis.

Directed Energy Deposition (DED)

DYNAMIC LAYER SELECTION

Dynamic Layer Selection adds a layer-by-layer inspection loop using a high-speed laser profilometer. Each layer is scanned in real-time for geometric accuracy, with point cloud output for post-process analysis. With closed-loop feedback enabled, the system automatically adjusts for deviations, ensuring precision builds and reducing scrap.

A laser profilometer scans each layer for shape accuracy. Closed-loop feedback auto-corrects deviations, reducing scrap and enabling consistent part geometry throughout the build process.

Four circular point cloud scans in pink, red, green, and blue on a black background, each showing deviations in surface geometry across different scan segments.
3D surface scan on a computer screen displaying topographic data of a rectangular metal build with elevation contours and color mapping in a grid layout.
Laser deposition setup with a FORMC controller managing laser power, thermal imaging of the melt pool, and graphs showing real-time laser power and melt pool width measurements.

MELT POOL MONITORING & CLOSED-LOOP CONTROL

DEDsmart® integrates Melt Pool Size and Temperature monitoring directly along the optical path. Both variables can be tracked live and controlled using closed-loop feedback, allowing laser power to adjust in real time. This ensures optimal heat input for consistent material properties and dimensional accuracy across the entire part.

DEDsmart® tracks melt pool size and temperature live. Closed-loop control adjusts laser power in real time, ensuring uniform heat input and material consistency.

Frequently Asked Questions About DEDSmart Software

DEDSmart is FormAlloy’s proprietary software platform for Directed Energy Deposition. It records and stores build parameter data, supports real time monitoring, and provides tools for build analysis, quality assurance, process validation, troubleshooting, and repeatability.
DED software controls and monitors important parts of the Directed Energy Deposition process. DEDSmart records build parameters, monitors process conditions, supports layer inspection, and provides data for analyzing and repeating successful builds.
DEDSmart works with FormAlloy’s in process monitoring systems to provide live information during a build. Optical monitoring can capture melt pool video, while melt pool monitoring tracks size and temperature to give operators greater visibility into the deposition process.
Melt pool monitoring tracks the size and temperature of the molten material during a DED build. DEDSmart can monitor these conditions along the laser optical path and use closed loop control to adjust laser power in real time.
Closed loop control uses live process data to make automatic adjustments during a DED build. With DEDSmart, melt pool conditions can be monitored and used to adjust laser power, helping maintain controlled heat input and consistent part properties.
DEDSmart supports quality control by recording build parameters and providing real time process information for analysis. Its monitoring capabilities can help identify process changes during production and provide recorded data for post build quality review and process validation.
Dynamic Layer Selection uses a laser profilometer to inspect each deposited layer for geometric accuracy. The system can provide point cloud data for analysis and, when closed loop operation is enabled, automatically adjust the build when deviations are detected.
Yes. DEDSmart records build parameter data and includes a playback function that allows successful process conditions to be reviewed and repeated. This supports process development, validation, and repeatable metal additive manufacturing.