Projects and guides
Industrial projects, demonstrators and application guides for metal additive manufacturing.
Choose the goal closest to your component, then compare relevant projects and guides for repair, coating, manufacturing or validation.
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Start with the engineering task: repair, coating, large-part manufacturing, quality, component design or procurement.
Published industrial project
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.
Published industrial project
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.
Published industrial project
Valve Seat and Wear Ring LMD Coating for Wear-Resistant Surfaces
Exafuse applied LMD / laser cladding to valve-seat and wear-ring geometries, combining layer planning, thermal control, finishing allowance and dye-penetrant inspection.
Published industrial project
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 published Exafuse case on thin-wall LMD, material zoning and long-build process planning using a 750 mm water-cooled nozzle demonstrator with Inconel 625 and Inconel 718.
Application guide
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.
Published industrial project
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.
Internal demonstrator
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.
Published industrial project
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.
Published industrial project
130 mm Drill: LMD Build-Up and Functional Coating
A 130 mm drill demonstrator showing how LMD can combine part build-up with a wear-resistant, antimagnetic functional coating in one planned manufacturing chain.
Published industrial project
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.
Public infrastructure project
Duisburg Bridge Components: More Than 750 kg Produced with LMD
Exafuse produced more than 750 kg of LMD components for a pedestrian bridge project in Duisburg, including six structural nodes and handrail elements.
Internal demonstrator
LMD Metal Powder Test-Wall Screening Case
How LMD test walls can screen new metal powder processability before committing to full component trials.
Internal demonstrator
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.
Published industrial project
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.
Published industrial project
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.
Published industrial project
Mining-Machine Dozer Blade Holder LMD Hardfacing Case
A published LMD hardfacing example on a curved mining-machine holder surface, presented without customer identity, process recipes or unsupported lifetime claims.
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Helps clarify the next step when the part problem and objective are clear but the right service is still open.
Business caseCompare repair with replacementUseful when replacement cost, lead time or downtime drives the decision.
Material guidanceAssess material suitabilityStarts 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.