Toward the Rapid Manufacturing of Lightweight Parts by Laser Directed Energy Deposition

Implementing lightweight structures reduces the mass of electric vehicles, thereby lowers the energy consumption, and thus, extends the maximum range. This work presents a methodology for the process design of laser-based Directed Energy Deposition (DED-LB) for the rapid manufacturing of lightweight parts. The methodology consists of various steps that help to manufacture defect-free multi-layer thin-walled parts. A component made of an aluminum alloy was manufactured using an extrusion profile as the substrate to test the methodology. The results indicate that lightweight structures can be manufactured reliably with the methodology. The results, therefore, contribute to establishing the process in the industry.