Intelligent layer height measurement in DED-LB processes with metal powder

LORTEK, in collaboration with DGH (a Groupe ADF company), has developed an innovative predictive control solution for DED-LB (Directed Energy Deposition – Laser Beam) metal additive manufacturing processes. This advance, made within the framework of the Tecmadiva project, allows automatic adjustment of key process parameters and ensures stable layer-by-layer deposition, improving quality, efficiency and traceability in advanced additive manufacturing.

The system has been designed to adapt flexibly to different industrial environments whether robotic cells, CNC equipment or other manufacturing platforms integrating into connected and modular production architectures.

One of the main challenges of the DED-LB process, also known as Laser Metal Deposition (LMD), is controlling the geometry and height of each deposited layer, an essential parameter for ensuring the repeatability and quality of the final part. Compared to classic manual or PID control systems, LORTEK has implemented a model-based predictive controller (Model Predictive Control, MPC) that dynamically optimises the laser power and deposition speed based on the thermal and geometric state of the part.

Tests carried out on LORTEK's flexible robotic cell DED-LB, which combines Cartesian kinematics and multi-axis robotics with multi-material feeding, demonstrate significant improvements: more uniform layers, less waviness, better surface finish and greater energy and metal powder efficiency.

The development is complemented by a real-time layer height measurement system based on a laser profilometer integrated into the manufacturing head. This device generates three-dimensional maps of the component and calculates geometric variations with micrometric precision, allowing the optimum distance between the head and the part (standoff distance) to be maintained and ensuring the correct interaction between the powder and the laser beam.

For its part, DGH has adapted its Trajectory Manager software to the DED-LB process, automating trajectory management and facilitating parameter control through an intuitive HMI interface. This connected architecture, based on industrial PLC, allows its integration into Edge, Cloud or hybrid platforms, in line with the principles of digitisation and traceability of the Tecmadiva project.

The combination of predictive MPC control and intelligent layer height measurement offers key advantages for the metallurgical and advanced manufacturing industries:

• Greater dimensional uniformity and fewer defects.
• Increased energy efficiency and metal powder utilisation.
• Adaptive automation of the thermal process.

This advance represents a decisive step towards smarter, more autonomous and efficient metal additive manufacturing, where the use of advanced sensors, data analysis and predictive control enables process optimisation and reduced energy impact.

With this technology, LORTEK reinforces its leadership in DED-LB additive manufacturing, contributing to the development of sustainable industrial solutions and the consolidation of Industry 4.0.

FULL NEWS: https://www.interempresas.net/Fabricacion-aditiva/613503-Medicion-inteligente-de-la-altura-de-capa-en-procesos-DED-LB-con-polvo-metalico.html