Additive manufacturing (AM) continues to transform how critical components are designed and produced, but widespread adoption remains hindered by challenges in process qualification and repeatability. Directed Energy Deposition (DED) in particular offers unmatched flexibility for repairing, coating, and building large, high-value metal parts—but process variability and lack of real-time feedback have traditionally slowed industrial deployment.
To address these challenges, FormAlloy has pioneered the integration of in-situ data collection and closed-loop control into every DED system it has produced since 2016. By combining melt-pool imaging, pyrometry, and profilometry, these systems deliver continuous process monitoring and enable adaptive, data-driven control. This approach moves beyond static reporting toward dynamic optimization—allowing operators to adjust parameters in real time, maintain process stability, and prevent defect formation before it occurs.
Closed-loop feedback provides a foundation for accelerated qualification by linking material behavior directly to processing parameters, significantly reducing the time required for parameter development. Moreover, this capability supports rapid alloy development and the fabrication of Functionally Graded Materials (FGMs), where composition and microstructure can be precisely tailored across a component. The resulting datasets not only validate builds but also create a rich digital thread that advances model-based certification pathways for future aerospace and defense applications.
This presentation will highlight recent FormAlloy demonstrations showing how in-situ data and closed-loop control improve consistency, enable reproducibility, and reduce post-build inspection requirements. Specifically, examples of aircraft landing gear repair and defense industry casting replacement will be presented. As the AM industry moves toward a data-centric manufacturing ecosystem, this approach establishes a clear case for how intelligent, feedback-controlled DED can accelerate qualification, expand design freedom, and deliver rapid, reliable manufacturing readiness for 2026 and beyond.
Learning Objectives:
Upon completion, participants will be able to understand how to use build data to enable qualification of Directed Energy Deposition (DED) repair and additive manufacturing applications.
Upon completion, participants will be able to use in-situ melt pool and other sensors to accelerate parameter development and enable qualified processes using Directed Energy Deposition (DED) technology.
