Exafuse produced more than 750 kg of metal components for a pedestrian bridge project in Duisburg using Laser Metal Deposition (LMD). The published scope includes six structural nodes and handrail components. The project connects design adaptation, deposition planning, long-duration production, process monitoring and independent validation in a real infrastructure application.
Project overview
| Project element | Published context |
|---|---|
| Application | Structural nodes and handrail components for a pedestrian bridge |
| Process | Large-part LMD / DED-LB/M |
| Published scale | More than 750 kg in total; individual components above 150 kg |
| Node production | Six structural nodes produced with LMD |
| Engineering work | CAD adaptation, path planning, parameter development, monitoring, finishing and inspection planning |
| Validation context | Independent project-specific support from Karlsruhe Institute of Technology (KIT) |
Why this project matters
The bridge components were not display pieces. They had to preserve the architectural intent, remain manufacturable with LMD, connect to adjoining structures and satisfy project-specific engineering requirements. That makes the project a useful reference for teams evaluating large, non-standard metal components.
The result does not mean that every bridge component or structural design is suitable for LMD. It demonstrates what can be achieved when geometry, deposition strategy, production planning and validation are developed as one project.
The engineering challenge
The original node geometry included overhangs, transitions, wall sections and connection points that required a manufacturability review. The task was to convert a sculptural digital model into a component that could be deposited, finished, joined and inspected without losing the design intent.
Design and manufacturing planning
CAD adaptation addressed unsupported features, wall thickness, transitions and interfaces. Selected wall sections were changed from 10 mm to 11 mm, with local reinforcement to 14 mm in higher-load areas. These values belong to this project and are not general design rules.
Path planning was equally important. Exafuse used a G-code post-processing workflow to manage tool orientation, material distribution and overlapping deposition zones on complex large geometry. In large-part LMD, the deposition path affects heat input, geometry and the evidence required for later assessment.
Result and scope
The published project documents more than 750 kg of LMD bridge components, including six structural nodes and handrail elements. It combines CAD adaptation, process development, production planning, monitoring and independent validation support. It is not a blanket approval for another bridge, material or structural design.
Information for a similar project
Provide the CAD model and drawings, approximate mass, target material, structural function, critical interfaces, acceptable design changes, finishing requirements, quantity, schedule and the required testing and documentation. Structural engineering, inspection and acceptance criteria must be defined for the individual application.
