LMD / DED-LB/M
Large parts, local material addition, repair and cladding
A laser creates a local melt pool while metal powder is supplied. Access, heat input, bead geometry and finishing determine suitability.
Technology
LMD, SLM/LPBF and additive-subtractive manufacturing for industrial metal parts.
Process selection follows component function, geometry, material compatibility, finishing and inspection. No machine is the best choice for every job.
Process selection
Three manufacturing approaches with different strengths.
Part size, detail, access and functional surfaces establish the initial direction. Material and inspection requirements may then change the choice.
SLM / LPBF
Compact parts with fine detail or internal channels
The component is built layer by layer in a powder bed. Orientation, supports, residual stress and post-processing belong in the initial plan.
Additive-subtractive manufacturing
Add material locally, then machine the functional surfaces
On this page, “hybrid” means combining additive build-up with subtractive finishing. It does not imply that LMD and SLM/LPBF are automatically combined in one component.
Equipment and build space
Three equipment routes for large build-up, complex paths and compact detailed parts.
The figures describe the published technical envelope. Part access, fixturing, material, finishing and inspection determine actual suitability.
CNC-based LMD system
Large build-up and circumferential cladding
The published component window reaches 2 × 1 × 2 m within a 4 m³ build space. Additional rotary axes support continuous deposition around cylindrical parts.
- Circumferential cladding of shafts, rollers, sleeves, bearing seats, hydraulic rods, screw sections, rings and cylindrical tooling
- Integrated scanning supports alignment, geometry capture and path registration
- In-house sensing and monitoring support process observation, height control and assessment of repeatable workflows
Robotic LMD system
Complex geometry with additional degrees of freedom
Exafuse developed the robotic cell for parts that require contour-following access, changing tool angles or additional positioning.
- Six robot axes and three positioning or rotary stations, with rotary-table support up to 1,000 kg
- Approximately 4 m² of accessible working area in the cell for larger parts and fixtures
- In-house scanning, path-planning, monitoring and control systems for project-specific process development
TRUMPF TruPrint 3000
Compact powder-bed parts with fine features
SLM/LPBF with a 400 mm platform diameter, 400 mm build height and 500 W single laser for parts whose value comes from compact detail.
- Suitable for internal channels, lattice structures, tooling inserts, compact impellers and functional prototypes
- Build orientation, supports, residual stress and post-processing are reviewed before manufacture
- Acceptance and material release remain specific to the component and application
Scanning, sensing and monitoring systems support alignment, process observation and technical assessment. They do not replace agreed component inspection or project-specific acceptance.
Parts and special-purpose systems
The equipment can be adapted around the component or developed as a project-specific LMD cell.
Exafuse can also develop LMD machine concepts for companies and special components when standard kinematics, fixturing, scanning or process monitoring are insufficient.
Rotational parts
Shafts, rollers, bearing seats, sleeves, hydraulic rods, screws, rings and cylindrical tooling.
Large and complex LMD parts
Structural nodes, housings, dies, impellers, nozzles, valve bodies, curved tooling and local modifications.
Compact SLM/LPBF parts
Internal channels, lattices, tooling inserts, compact impellers and prototypes within the published build envelope.
Special-purpose machines and cells
Project-specific LMD cells, scanners, positioners, fixtures, sensing, monitoring, control and path planning.
Project-specific machine development
Kinematics, scanning, fixturing, sensing and software as one coordinated system.
The scope may range from a component-specific fixture to a dedicated cell or machine concept. Integration, machine safety, acceptance and delivery scope are defined separately for each project.
From data to inspected component
Additive manufacturing does not end with deposition.
A workable manufacturing plan connects build-up, finishing and inspection in one process chain.
1
Component requirements
Capture geometry, material, function, quantity and timing.
2
Manufacturing process
Compare LMD, SLM/LPBF and additive-subtractive manufacturing technically.
3
Build and finishing
Define the deposition or build strategy, machining allowance, heat treatment and surface condition.
4
Inspection and acceptance
Agree inspection features, documentation and acceptance criteria before manufacture.
Project examples
Large components, thin-wall build-up and functional layers create different demands.
The examples document specific applications. Material and acceptance requirements remain specific to each new component.
Large component
Duisburg bridge components
Structural nodes with CAD adaptation, robotic path planning, monitoring and project-specific validation.
View project
Thin-wall build
750 mm multi-material nozzle
An LMD demonstrator with distinct Ni-based material zones and water-cooled geometry.
View project
Build and coat
130 mm drill
LMD part build-up and a tungsten-carbide-containing functional layer in one coordinated manufacturing sequence.
View project
Monitoring and inspection
Process data supports assessment but does not replace component inspection.
Image and sensor data can reveal deviations and support process development. Acceptance still requires agreed inspection methods, physical evidence and engineering responsibility.
Process selection
Describe the component, material, dimensions and required function.
Exafuse will identify which process is worth assessing and what information is still missing.
Request technical reviewRecommended next steps
Pick the next page by what you need to decide.
Continue with a relevant service, case study, technical article, FAQ or feasibility request.
01
Compare the manufacturing processes
Use the process comparison when part scale, local buildup, fine detail or internal channels determine the manufacturing choice.
Public infrastructure projectDuisburg Bridge Components: More Than 750 kg Produced with LMDArticleLarge Structural LMD for Bridge Components: Lessons from the Duisburg Bridge ProjectArticleWhat Is Laser Metal Deposition (LMD) and When Should Industrial Buyers Use It?FAQLaser Metal Deposition (LMD): applications, limits and project inputsPageTechnology and equipment
Metal AMStart manufacturing RFQ4 more related items are available through the linked hub pages.
02
Define inspection before production
Match dimensional inspection, surface testing, metallography and documentation to the component function and project risk.
Public infrastructure projectDuisburg Bridge Components: More Than 750 kg Produced with LMDArticleLarge Structural LMD for Bridge Components: Lessons from the Duisburg Bridge ProjectArticlePorosity in LMD/DED: Root Causes, Detection, and Practical PreventionFAQQuality and inspection: what monitoring and testing can establishServiceQuality
Quality alignmentRequest validation plan2 more related items are available through the linked hub pages.
03
Review current research topics
Explore public work on wider deposition tracks, process monitoring and additive tooling without treating research results as production qualification.
PageResearch & projectsArticleResearch Spotlight: BreitBahnDED and Why Wider Beads Matter for Industrial ProductivityArticleMonitoring and Control in DED/LMD: What In-Process Signals Mean for Quality
Metal AMStart manufacturing RFQ2 more related items are available through the linked hub pages.