Proof and guides
Case studies, application guides and proof paths for industrial metal additive manufacturing decisions.
Choose the project intent closest to your part, then browse the proof pages and guides that match that failure mode, build goal or validation need.
Find relevant proof
Browse proof and guides by project problem.
Start from the closest technical intent: repair, coating, large-part build, quality risk, OEM design or procurement pressure.
Case study
Forging Hammer Repair and Coating with LMD
How Exafuse uses Laser Metal Deposition to rebuild and reinforce forging hammer working faces, including a 170 mm radius round-die coating example with 20 mm Inconel 625 and laser polishing.
Application guide
Gear, Pinion and Toothed-Part Repair: When LMD Is Worth Evaluating
LMD can be worth evaluating for toothed industrial parts when the damage is local, the base component still has value, the material can be identified and the repaired geometry can be...
Application guide
Hot-Forming Die and Tooling LMD Hardfacing Review
How Exafuse evaluates hot-forming dies and tooling wear zones for LMD repair or hardfacing, using tungsten-carbide coating imagery as public coating context.
Application guide
Rolling Die Cylinder Coating with LMD Laser Cladding
How Exafuse developed a laser-cladding route for a cylindrical rolling-die component using material screening, diameter build-up, crack and pore review, microscopy and HV1 hardness profiles.
Case study
Valve Seat and Wear Ring LMD Coating with Crack-Controlled Co-Based Wear Material
How Exafuse used LMD / laser cladding, ring-specific layer planning and dye inspection to evaluate a Co-based wear-resistant coating route for valve seat and wear ring geometries.
Application guide
Large Cylindrical Part LMD Cladding with Process Video
A visual case for LMD / laser cladding on a large cylindrical component, showing process access, rotation logic, surface planning and a short deposition video.
Research note
Research Topic: Detecting and Reducing Porosity Risk in LMD
Porosity risk in LMD should be treated as an evidence question, not as something checked only by looking at the final surface.
Internal demonstrator
750 mm Multi-Material LMD Nozzle Demonstrator Case
A public proof case for Exafuse thin-wall LMD, material zoning and long-build process planning using a 750 mm water-cooled nozzle demonstrator with Inconel 625 and Inconel 718.
Case study
DfAM Bridge Node Manufacturability Review for LMD
How bridge-node geometry illustrates why metal AM projects need DfAM, manufacturability review, wall strategy, finishing and validation planning before production.
Case study
Nobufil Extrusion Screw Repair: Short-Lead-Time LMD Rebuild of a Cracked Stub Shaft
How Exafuse repaired a cracked Nobufil extrusion screw shaft with a targeted DED/LMD route when no replacement screw was immediately available.
Research note
Functionally Graded LMD Pipe Demonstrator
A publication-ready case on functionally graded LMD thinking: material zones, controlled transition, interface risk and validation boundaries for a pipe or tubular demonstrator.
Case study
24-Hour Inconel 718 Coating Repair for an Undersized Spindle
How Exafuse recovered an undersized machined spindle feature by applying a targeted Inconel 718 LMD coating, leaving machining allowance and enabling dimensional recovery.
Case study
130 mm Bombenbohrer LMD Build-and-Coat Workflow: From Powder to Functional Drill
Exafuse publicly showed a 130 mm "Bombenbohrer" drill workflow in which Laser Metal Deposition (LMD) was used for both part fabrication and final surface coating.
Case study
Turbo Generator Rotor Wedge Coating with LMD: Heat-Controlled CuNi2SiCr on Copper Substrate
Exafuse developed an LMD coating route for turbo generator rotor wedges where the coating challenge was not only wear and corrosion resistance.
Case study
Duisburg Bridge Components with LMD: 750 kg+ Nodes and Handrails from CAD to Validated Production
Exafuse manufactured more than 750 kg of metal components for a pedestrian bridge project in Duisburg using Laser Metal Deposition (LMD).
Case study
LMD Metal Powder Test-Wall Screening Case
How LMD test walls can screen new metal powder processability before committing to full component trials.
Case study
Inconel 718 Thin-Wall LMD Demonstrator Case
A 300 mm Inconel 718 thin-wall LMD demonstrator case for discussing physical proof, wall continuity, finishing and application-specific validation boundaries.
Case study
3 kW Helical Impeller Metal 3D Printing Prototype Case
A metal 3D printed helical impeller prototype case for manufacturability review, rotating geometry feedback and process-selection discussion.
Case study
LMD Part Modification and Feature Addition Case
How Laser Metal Deposition can add local features to an existing metal part when access, substrate, finishing and inspection make the route practical.
Case study
Mining-Machine Dozer Blade Holder LMD Hardfacing Case
A public hardfacing proof for LMD wear-resistant coating on a curved mining-machine holder surface, framed without customer identity, recipes or unsupported lifetime claims.
Next action
Move from proof to your own part.
Compare public proof with your own part, then choose the most practical next step.
For cases where the problem is clear but the service, process or next step is still open.
Business caseCompare repair with replacementUseful when replacement cost, lead time or downtime drives the decision.
Material screenScreen alloy directionStarts from wear, corrosion, temperature, base material and target surface.
Direct contactRequest a Teams or phone callBest for NDA questions, unclear data or urgent cases that need a short conversation first.