TECHNOLOGY

FormAlloy’s award-winning directed energy deposition (DED) systems enable customers to FORM, ENHANCE, and REPAIR metallic parts that go beyond the bounds of traditional manufacturing. FormAlloy's 3D metal printing technology utilizes DED to create metallic parts to near-net shape, while increasing the design envelope and providing a more economical solution than producing the same part with conventional methods.

FORM

With FormAlloy’s technology, customers and clients will be able to confidently FORM parts 2-100x faster than other methods and produce high quality, repeatable builds with in-process monitoring and control features. The X&L-Series systems reduce machining time and nearly eliminate material waste, particularly with high-value materials such as titanium and Inconels. Additively Manufactured parts from FormAlloy can provide design features that can’t be achieved with conventional manufacturing methods, such as internal cooling channels and multi-metal parts. 

 

FormAlloy’s DED process deposits metal with a coaxially aligned laser/powder nozzle. With the FormAlloy process, clients and customers can achieve faster build times, superior material capabilities, and larger build envelopes compared with powder-bed technologies such as direct metal laser sintering (DMLS) and binder jetting. 

 

FormAlloy’s DED process can produce parts with dimensions from less than 1 mm to greater than 1 meter with bead widths from 500 micron and up.

ADDITIVE MANUFACTURING TECHNOLOGY
NASA ROCKET NOZZLE PART
INCONEL 625
ADDITIVE MANUFACTURED DOOR HANDLE
AS-PRINTED RESOLUTION VS SURFACE FINISHED
INCONEL 625

ENHANCE

FormAlloy’s technologies can ENHANCE existing products by adding dimensional features, depositing bi-metallic and gradient material systems, and laser cladding for superior performance.

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With the capability to add features and multiple materials, FormAlloy systems provide the ability to improve legacy and new products with geometric and alternative material additions. The additional features can provide a wide range of benefits from improved mechanical properties to higher temperature capabilities for improved performance and extended life.

 

For additive enhancements, structures can be added onto work pieces just like depositing on a flat plate. Reinforcing structures such as ribs, grids, and plates can be strategically placed on components. Functionally graded material (FGM) systems can also be built in a single-step additive process to transition materials from one to another while reducing the residual stress during the build. The FGM system then delivers the beneficial properties of specific alloys at localized parts of the components. 

 

In addition to additive enhancements, FormAlloy's cladding capability can be used to create wear and corrosion-resistant coatings that are 100% dense and bonded metallurgically. DED provides very low dilution between the coating and substrate and allows for fine microstructures, precise control of the coating thickness and reduced distortion into the base part.

MULTI-MATERIAL COMPONENTS
IN718 / IN625 / STELLITE 6 (LEFT)
IN625 / COPPER (RIGHT)
LASER CLADDING TECHNOLOGY
COPPER COMPONENT + INCONEL 625 CLAD
PROVIDES MECHANICAL STRENGTH TO A CONDUCTIVE COPPER PART

REPAIR

Formalloy’s REPAIR technology can be used to rebuild damaged or worn areas of valuable machine components, dies or molds. LMD produces 100% dense, metallurgically bonded features to the damaged part, with layer thickness from microns and up, thus enabling a variety of repair applications that require minimal post-process machining.

SHAFT REPAIR PROCESS
4140 STEEL
FINISHED SHAFT REPAIR
4140 STEEL

See our News & Events page for upcoming trade shows & demonstrations, or Contact us for further information and pricing.

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