ExafuseMetal additive manufacturing
Capability screen

Use machine envelope, material family, duty and validation needs to decide what is technically worth reviewing.

Technology

Technology at Exafuse: LMD, SLM and hybrid additive routes.

Exafuse compares laser-based metal additive routes by part size, feature detail, repair need, performance target, finishing plan and inspection scope.

6-axis robotic LMD system for complex geometry, repair and cladding

LMD, SLM, hybrid

Process choice should come from part function, geometry, finishing and inspection.

This page should not feel like a list of machines. It explains the route: when LMD fits, when SLM fits, when hybrid thinking is useful and which data is needed before a reliable decision.

Visual decision support for LMD, SLM and hybrid additive route selection

Process route

Clarify the part task first, then select the machine route.

  • Evaluate LMD / DED-LB/M for large parts, local build-up, repair and cladding.
  • Evaluate SLM / LPBF for compact, detailed geometry and internal-channel value.
  • Think hybrid when build-up, finishing, inspection and functional surfaces need to be planned together.
Check LMD or SLM Read selection matrix

Process chain

From part data to finished and inspected component.

Every LMD, SLM or hybrid project connects process planning, material choice, build strategy, finishing and inspection. Treating them together makes feasibility clearer from the first review.

1IntakeGeometry, material, duty, deadline, acceptance criteria.
2SelectLMD, SLM or hybrid route based on size, detail and function.
3BuildDeposition path, powder-bed route, heat input or hybrid build strategy.
4FinishMilling, grinding, heat treatment or polishing as needed.
5InspectMicroscopy, metallography and agreed documentation scope.

Flagship proof

Duisburg bridge components show large structural LMD from CAD to validated production.

The public bridge case connects large LMD components, CAD adaptation, path planning, monitoring, validation support and final inspection in one reference.

Large LMD-manufactured bridge node component

750 kg+ LMD components

Structural nodes, handrails, CAD redesign, path planning, monitoring and validation in one public large-LMD reference.

Open the case study when you are evaluating large Metal AM parts, robotic LMD, long builds or validation logic.

Open bridge case study

Capabilities and equipment

CNC-based LMD machine, 6-axis robotic LMD, TRUMPF SLM, finishing, quality and data support.

The equipment story is shown once here: two LMD routes for scale and geometry, SLM / LPBF for compact detail, post-processing, quality support and data-led process understanding.

CNC-based LMD machine at Exafuse

CNC-based LMD machine

Large controlled LMD build space for near-net-shape parts, repair and cladding.

  • 4 m3 build space
  • Components up to 2 m x 1 m x 2 m (x-y-z)
  • Coaxial melt-pool monitoring and advanced sensors
  • LMD wall widths from 1.8 mm fine detail to 3.7 mm robust structures
6-axis robotic LMD system for complex geometry, repair and cladding

6-axis robotic LMD

Robotic deposition for complex shapes, larger reach and contour-following surfaces.

  • 6-axis robotics with 2-axis positioners
  • Rotary table supports components up to 1,000 kg
  • 6 x 5 x 4 m installation space
  • Zoom optics adjust wall thickness from 1.5 mm to 4.5 mm
TRUMPF TruPrint 3000 SLM machine for compact detailed metal additive manufacturing

SLM / LPBF machine

TRUMPF TruPrint 3000 for compact detailed metal parts.

  • 400 mm diameter build platform
  • 400 mm build height
  • 500 W single-laser system
  • Fit for internal channels, lattices and fine features
Finished component after LMD deposition and post-processing

Post-processing

Finished geometry matters as much as the deposited material.

  • Shows the step from LMD build-up to usable surface
  • Machining, grinding or other finishing is planned from the first feasibility review
  • Keep tolerance and heat-treatment claims project-specific until verified
Inspection equipment for additive manufacturing quality review

Quality support

Inspection and metallographic preparation support validation planning.

  • Microscopy and sample preparation where evidence is required
  • Useful for bond, layer and defect-risk discussions
  • Approved inspection visuals support validation planning without exposing customer data
LMD process monitoring and melt-pool signal view

Computing / AI

Process monitoring supports data-led understanding of LMD and SLM work.

  • External monitoring and process observation can support R&D and validation discussions
  • Computing infrastructure helps handle process data and AI-assisted process understanding
  • Positioned as process observation and data support, not automatic quality control

Multi-material proof

750 mm water-cooled nozzle with two Ni-based material zones.

The nozzle case is a strong signal for material zoning, thin-wall LMD planning and long build stability. It does not replace part-specific release for other geometries.

Close process view of a 750 mm multi-material LMD nozzle demonstrator

Material zoning

750 mm water-cooled nozzle with two Ni-based material zones.

  • Use Inconel 625 and Inconel 718 in defined zones
  • Plan thin walls, cooling ribs and heat input together
  • Evaluate long builds through process stability
Read nozzle proofRequest multi-material review

Drill workflow proof

130 mm build-and-coat drill: one image, one clear manufacturing logic.

The drill shows LMD as both the manufacturing route and the functional coating route. The point is practical: geometry, coating, finishing and inspection must be reviewed together.

130 mm drill during Laser Metal Deposition build and coating workflow

Build and coat

130 mm build-and-coat drill: one image, one clear manufacturing logic.

  • Build the part geometry with LMD
  • Apply the functional coating locally
  • Plan finishing and release evidence per part
Open case studyRead build-and-coat guide

Research connection

Research belongs on the technology page when it explains the process route.

BreitbahnDED, EIS-KW and monitoring topics show how Exafuse connects process understanding, wider tracks, tooling questions and validation without turning research into blanket performance promises.

BreitbahnDED research process visual

Research with boundaries

Public research explains process direction, not automatic part release.

  • frame wider DED/LMD tracks and productivity questions
  • connect tooling, heat and monitoring topics to process choice
  • make validation and buyer input data visible as part of the route
Open research page Read BreitbahnDED Open related page

Validation stack

A good validation plan separates geometry, metallurgy, surface condition and documentation.

Quality is not one final inspection step. For LMD, laser cladding and SLM, the project should define which evidence actually supports the part function before production starts.

Metallographic preparation and inspection support

Quality evidence

Inspection scope and acceptance criteria belong in the technical review, not only after a problem appears.

  • Define geometry, datum strategy and machining allowance early.
  • Review bond, dilution, microstructure and defect risk as separate evidence categories.
  • Plan documentation around part function, buyer requirements and acceptance criteria.
Request validation planRead inspection guide