The addition of multiple laser diodes will speed up the production of 3D printed parts

Laser melting systems are increasingly being used in high value areas such as aerospace and automotive. However, this process has its limitations because it relies on a mirror to deflect a single laser, which to some extent limits the speed of the system.

A new process called Diode Area Melting (DAM), developed by the University of Sheffield, UK, can overcome this by using large area melts in parallel with a single laser diode array. These laser beams turn on or off as the powder bed moves, making it faster and more energy efficient.

Dr. Kristian Groom, Department of Electronics and Electrical Engineering, said: "Our research challenged the industry's longstanding belief that low-power diode modules can not be adequately melted due to their low power and poor beam quality."

"The key to the success of the DAM process is an improvement over the short wavelength laser array (808 nm), where the addition of a single collimated and focused beam allows melting points in excess of 1400 ° C in a few milliseconds to produce full density stainless steel 17-4 parts. "

The inventors of the DAM process, Dr. Groom and Dr. Kamran Mumtaz (Department of Mechanical Engineering), plan to continue investigating the laser interaction and broaden the system to include polymer processing. The team believes it is possible to combine the wavelength targeting of a range of materials with a single machine.

It is reported that the study has received funding from the Engineering and Physical Sciences Research Council (EPSRC).