SBIR-STTR Award

Optonicus proposes development of the WALAM-ABS (Wide-Area Laser Additive Manufacturing in Metals with Adaptive Beam Shaping) laser additive manufacturing (LAM) system. The WALAM-ABS metal additive manufacturing system will solve long-standing drawbacks imposed by current single-point selective laser melting LAM technology through the use of wide-area processing based on proprietary multi-beam fiber-array laser systems. The proposed system will adapt high-power coherent fiber-array and adaptive beam control technologies originally developed for DoD directed energy applications. In Phase II, Optonicus will develop a fully functioning WALAM-ABS system, which will be delivered to ONR for further evaluation. Optonicus has concrete plans to commercialize this technology for DoD defense markets and civilian applications in Phase III.

Benefit:
Metal LAM using laser energy sources is a rapidly emerging technology that, with further innovations such as in the proposed WALAM-ABS R&D, can provide a competitive advantage to the United States in the ongoing worldwide competition for new high-tech jobs and markets. Manufacturers worldwide continue to seek out technologies that can improve LAM system productivity through increasing throughput, energy efficiency, productivity, and profitability. Potential military applications of the WALAM-ABS system include repair of metallic components, and production of small quantities of out-of-production or long lead-time metallic components. Commercial industry sector applications include aerospace, shipping, transportation, rail, automobile, medical, high quality engine components, structural parts, mechanical or electrical parts, medical prosthetics, jet engine blades and other high-value complex metal components currently supplied by machining techniques.

Keywords:
Laser Additive Manufacturing, Laser Additive Manufacturing, Material Processing, Low Defect Microstructure, Fiber-Array Laser Source., Laser Beam Shaping Metal Additive Manufacturing, Laser-Based Metal Powder Processing, Wide-Area Laser Additive Manufacturing, Metal Additive Manufacturing

Optonicus proposes development of the Wide-Area Laser Additive Manufacturing in Metals with Adaptive Beam Shaping (WALAM-ABS) laser additive manufacturing (LAM) system. The WALAM-ABS metal additive manufacturing system will solve long-standing drawbacks imposed by current single-point selective laser melting LAM technology through the use of wide-area processing based on proprietary multi-beam fiber array laser systems. The proposed Phase II WALAM system will adapt high-power coherent fiber-array and adaptive beam control technologies originally developed for DoD directed energy applications. Benefits include a revolutionary 10-fold build rate increase with a 2-3-fold improvement in 3D printing spatial resolution with real time control of thermal gradients and wide area in-situ sensing of the power bed material and solidification track.

Benefit:
Metal additive manufacturing using laser energy sources is a rapidly emerging technology that, with further innovations such as in the proposed WALAM-ABS R&D, will provide a competitive advantage to the United States in the ongoing worldwide competition for new high-tech jobs and markets. Manufacturers worldwide continue to seek out technologies that can improve LAM system productivity through increasing throughput, energy efficiency, productivity, and profitability. Potential military applications of the WALAM-ABS system include repair of metallic components, and production of small quantities of out-of-production or long lead-time metallic components. Commercial industry sector applications include aerospace, shipping, transportation, rail, automobile, medical, high quality engine components, structural parts, mechanical or electrical parts, medical prosthesis, jet engine blades and other high-value complex metal components currently supplied by machining techniques.

Keywords:
Laser Additive Manufacturing, Material Processing, Laser-Based Metal Powder Processing, Low Defect Microstructure, Wide-Area Laser Additive Manufacturing, Laser Beam Shaping Metal Additive Manufacturing, Fiber-Array Laser Source., Metal Additive Manufacturing