years
6+
Working with DED/LMD across university research, robotic systems, and industrial Exafuse projects.
Evidence base Field notes
Sources + Experience
Notes that stay tied to real LMD work.
This page collects the numbers, source links, and field context behind the site. I want the writing to feel like engineering notes: specific where the source supports it, careful where the data is conditional, and clear about what AI can and cannot prove.
first LMD paper
2018
Co-authored a Procedia CIRP paper on laser metal deposition of lattice structures by columnar built-up.
M.Sc. grade
97%
Lasers and Photonics at Ruhr University Bochum, with Faculty Prize / Best Student.
systems layer
ROS2
Sensor/camera control and real-time data pipelines around DED/LMD process monitoring.
Numbers with source context
Concrete LMD/DED facts I can point to
These numbers are not universal design rules. They are cited anchors that help readers understand scale, process behavior, and claim boundaries.
10^3-10^5 C/s
Typical DED cooling-rate range
A DED state-of-the-art review reports typical cooling rates in this range. That is one reason I care about process history and thermal context.
Ahn, Directed Energy Deposition (DED) Process: State of the Art30-200 um
Common powder particle diameter range
The same DED review gives this as a common powder diameter range for laser additive manufacturing DED processes.
Ahn, 2021<30%
General material usage efficiency reported for LAM-DED
The review notes that specific cases can be much higher, but the general reported efficiency is often below this value.
Ahn, 202110-30%
Dilution-ratio window cited for proper first-layer dilution
The review summarizes literature proposing this range. Outside it, lack-of-fusion and keyhole-type risks become part of the discussion.
Ahn, 20211-3 mm vs <200 um
LMD focus size compared with SLM in Sharma et al.
Our lattice-structure LMD paper contrasts LMD's larger focus size with SLM's smaller focus, which is why the process design logic is different.
Sharma et al., Procedia CIRP 20181070 nm / 450 W / 2 mm
Parameters from Manish Sharma's 2018 LMD paper
The published experiment used a ytterbium fiber laser, 316L powder, a 2 mm focus size, and a 3 mm substrate for columnar built-up lattice experiments.
Sharma et al., Procedia CIRP 201845-90 um
316L powder size in the 2018 lattice experiment
I keep details like this visible because they are more useful than a generic portfolio claim.
Sharma et al., Procedia CIRP 20185-10 mm / >95%
BreitbahnDED project targets
From my public profile material: broad-track DED goals include rotating multi-spot optics, 5-10 mm wide tracks, multimodal monitoring, layer-to-layer control, and a >95% powder-utilization target. This is a project target, not a published result claim.
Manish Sharma public profile materialField notes
What experience changes in the writing
The personal layer should not sound like vague authority. It should show how I think when an LMD claim, RFQ, monitoring signal, or AI recommendation looks too confident.
Height is not a cosmetic variable.
In DED/LMD, stand-off distance and layer-height errors add up quickly. I treat height sensing, toolpath correction, and post-machining allowance as part of the process plan, not a late fix.
A camera is not a certificate.
Coaxial vision, pyrometry, and melt-pool features are useful because they tell us what the process was doing. They only become strong evidence when they are connected to inspection results.
RFQs fail when they hide risk.
A weak request is not always a short request. The real problem is missing material grade, damage depth, tolerance, operating conditions, or inspection criteria.
Traceability is a product feature.
For industrial DED/LMD, parameter logs, change control, build reports, inspection reports, and deviation tracking are part of the work, not paperwork at the end.
Industrial proof
Public Exafuse cases that anchor the claims
These are public company case studies, not private project details. They make the site more concrete by showing the kind of industrial LMD problems behind the frameworks.
CS15
Duisburg Bridge Components
750 kg+6 nodes219 h38 km1M+ images
Large structural LMD is a CAD-to-production system problem: manufacturability review, path planning, parameter development, monitoring, independent validation and final inspection.
Open Exafuse sourceCS01
Forging Hammer Repair
10-20 mmimpact wearbond + toughness
A credible hammer repair is not one hardness number. It requires surface preparation, crack context, layer strategy, finishing, bond quality and release evidence.
Open Exafuse sourceCS10
Nobufil Extrusion Screw Repair
local crackno sparefinish after LMD
Repair value often comes from a local failure with a large downtime risk. The damaged material must be removed before rebuilding, not hidden below new deposition.
Open Exafuse sourceCS13
130 mm Build-and-Coat Drill
130 mmbuild + coatWC-containing alloy
LMD can combine geometry creation and functional surface strategy when material compatibility, coating duty, finishing and validation are planned together.
Open Exafuse sourceReference map
What the 500-record map is good for
This is a map of the research terrain, not a claim that every paper was read end to end. It helps keep the site vocabulary aligned with real LMD/DED research.
Reference map
500
LMD/DED records in the map
OpenAlex reference map across eight LMD, DED, laser cladding, melt-pool monitoring, and machine-learning queries. I use it for orientation and vocabulary; exact claims still come from checked sources.
Top venues in the map
Additive Manufacturing 54 records
Materials & Design 27 records
International Journal of Advanced Manufacturing Technology 19 records
Journal of Materials Processing Technology 17 records
Materials 16 records
Exact claims on this site are based on source-specific citations. The broader map is useful for topic coverage, terminology, and deciding which content needs more research depth next.
Sources
Public sources used for this evidence pass
NIST Directed Energy Deposition overview → ASTM DED standard announcement → Ahn - Directed Energy Deposition Process: State of the Art → Sharma et al. - Laser metal deposition of lattice structures by columnar built-up → NIST/JOM 2024 - parallel monitoring in powder-blown DED → Optics and Lasers in Engineering 2019 - optical monitoring for laser-aided DMD → OpenAlex 500-record LMD/DED literature map → LinkedIn / public profile →
Exafuse homepage → CS15 bridge components → CS01 forging hammer repair → CS10 extrusion screw repair → CS13 build-and-coat drill → A03 LMD buyer guide → A04 LMD vs SLM → A06 large-part LMD → A12 monitoring and control → A21 BreitBahnDED → A25 year in powder → A29 forging hammer evaluation → A37 neural image processing →
Established domain
Follow the LMD/DED evidence trail
Industrial AI ThesisSense, Model, Decide, Verify.Open →Core LMD-AI SourcesCurated source map for AI and Laser Metal Deposition.Open →Industrial Proof MapPublic Exafuse cases and article signals.Open →LMD RFQ ToolkitSchemas, prompts, rules, and checklists.Open →Full Site MapEvery page and public machine-readable asset in one linked map.Open →