Manufacturing of complex geometries with overhang by means of DED-LB technology

This thesis investigates the realization of complex metallic geometries through Laser Directed Energy Deposition (DED-LB) technology, with the aim of assessing the feasibility and limitations of the process when applied to challenging shapes. The study focuses on two representative case studies characterized by unsupported overhangs, inclined surfaces, and the requirement of continuous deposition. The methodology involves defining planar slicing planes based on the geometric features of the components, in order to reproduce the sectional layers used for the deposition process. The slicing was performed using Rhinoceros Grasshopper, which was employed to extract the necessary point coordinates from the CAD model. Subsequently, a MATLAB script was developed to generate the corresponding G-code, customized according to the capabilities of the Prima Additive LASERDYNE 430® system and designed to control layer alternation, pauses, and retraction routines. Experimental trials were conducted to evaluate both the geometrical accuracy and the overall quality of the manufactured parts. The results confirm the feasibility of producing complex tubular junctions through L-DED, while highlighting critical aspects such as material accumulation, thermal management, and dimensional accuracy, particularly in curved or inclined regions. Overall, the work demonstrates that, with a suitable planar slicing strategy and dedicated G-code generation, L-DED technology can effectively manufacture geometrically complex parts, providing a reproducible framework for the automation of toolpath generation and the optimization of deposition parameters.