Paolo Russo
Manufacturing of complex geometries with overhang by means of DED-LB technology.
Rel. Eleonora Atzeni, Alessandro Salmi, Adriano Nicola Pilagatti. Politecnico di Torino, Corso di laurea magistrale in Automotive Engineering (Ingegneria Dell'Autoveicolo), 2025
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Abstract
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
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