Large-Scale Robotic AM System
Penn State ARL

Custom-configured and designed, this DED system features the most advanced, state-of-the-art capabilities for high-deposition rate additive manufacturing. A six degree-of-freedom articulated robot and two-axis rotary positioner synchronously locate the processing head and workpiece for deposition. The system can accommodate large structures fitting within a 2m x 3m x 3.5m envelope and can also produce a wide variety of complex geometries given the robotic configuration’s positioning flexibility. Up to 12 kW of laser power is directed through a water-cooled two-axis beam scanning process head for programmable energy distribution. Wire or powder feedstock can be used for fabrication with deposition rates in excess of 10 kg/hr. The integrated wire-based system includes hot-wire capabilities for wire pre-heating. By combining the most advanced processing capabilities into one integrated platform, this system represents the next generation of large, rapid additive manufacturing.

Robot

LENS MR-7 Optomec

Multiple powder-feed capabilities for deposition and full consolidation of complex components within a controlled inert gas environment. This system provides a working envelope of 30 cm length by 30 cm width by 15 cm height. The Optomec system is capable of near-net fabrication of components and requires final machining. Although the system is capable of producing parts having complex geometries, it cannot produce geometries having significant projection or overhang without support.

Optomec LENS MR-7

HPHD Penn State ARL

Utilizing 3rd-generation AeroMet high-deposition capabilities, our first in-house built DED system is capable of larger build volumes. This High-Power High-Deposition (HPHD) system utilizes a laser with power levels up to 12 kW in a customizable build volume. Rectilinear builds can reach 100cm x 30cm x 45 cm and cylindrical builds can reach 60cm in diameter and 30 cm high. A custom cladding head with water-cooled optics and an inert gas enclusure make this a truly powerful system.

HPHD