IMTS 2022 Conference: DED Manufacturing of Large Critical Components – Pushing the Limits of Metal Additive Manufacturing (AM)


About the presentation

This presentation focuses on the additive manufacturing of large metal parts with the new multi-nozzle directed energy deposition (DED) manufacturing technology. Recent advances in technology now make printing large parts economically feasible and technically superior. The presentation features additive manufacturing of NASA’s RS-25 engine nozzle liner. This piece stands 111″ tall, has a base diameter of 96″, and weighs approximately 4,100 pounds. The construction approach of this liner is discussed to highlight various challenges in printing large parts and the strategies adopted to mitigate these challenges. The objective of the presentation is to raise awareness of the advancement of metal additive manufacturing (AM) capabilities. This is achieved by demonstrating the ability to print large, complex parts with challenging materials while targeting critical industrial applications. At the same time, the presentation aims to educate attendees on the various challenges posed by large-scale printing and how industry partners are working together to solve these problems. Finally, the presentation shows how various industry teams have come together with government agencies to advance existing technologies and develop new ones to solve tough manufacturing challenges and advance metal additive manufacturing to a new level of manufacturing. .

Powered by AMT and managed by GIE Media, The IMTS 2022 conference features 69 different sessions you won’t want to miss so register today. Focused on a range of topics that include process innovation, plant operations, quality/inspection and automation, The IMTS 2022 conference addresses improving productivity; improve the quality of parts; and develop a stable, skilled workforce to reduce the cost of manufacturing in the United States and create new levels of market demand.

Meet your presenter
Bhaskar Dutta is the President and COO of DM3D Technology. Dutta has over 30 years of experience in the field of metallurgy and metal processing, including 17 years in the AM industry. He has several publications and technical presentations in the field of AM, as well as two co-authored books and several book chapters. He also has five patents and five patents pending on metal AM. He is a member of ASM International and of the AMPM program committee. Bhaskar was part of the winning team for SME’s Aubin AM Case Study Award in 2021.

Farhad Ghadamli is the Chief AM Engineer at DM3D Technology. During his professional career, he has worked with different 3D printing equipment manufacturers as well as the Eaton Polymer and Nanocomposite Group and the Eaton Additive Manufacturing Center of Excellence in Southfield, Michigan. He has experience with various technologies, such as FDM, DLS, DMLS, SLS, SLA, Bound Metal Deposition, Binder Jetting and Direct Metal Deposition (DMD). Ghadamli holds an MS and BS in Mechanical Engineering from the University of California, Davis. In 2021, he was one of the recipients of the SME Aubin AM Case Study Award as well as the SME President’s Award for his work as President of Metro Detroit SME. He was recognized as one of the 2015 SME 30 under 30 Future Manufacturing Leaders.

Mark Lewan is a senior engineer at DM3D. He is responsible for design engineering, CAD/CAM software and the machining department at DM3D. Lewan has 31 years of industry experience, including 20 years in AM. Mark has co-authored several publications and has three patents and two patents pending on AM technology. Mark was part of the winning team for SME’s Aubin AM Case Study Award in 2021.

Robert Fortuna is the production supervisor at DM3D. He is in charge of all AM production work. He has 41 years of experience in the industry, including 15 years in AM. Prior to DM3D, Fortuna worked in various industries including building laser welding machines and assembling laser welded filters. Fortuna was part of the winning team for SME’s Aubin AM Case Study Award in 2021.

Vijayavel Bagavath Singh is Senior Manager – DMD Systems in DM3D Technology. He is responsible for the design and construction of DMD systems. Singh holds a master’s degree in electrical engineering with 26 years of experience in controls engineering. His areas of expertise include metal 3D printing, laser, CNC and robotic processes. He is co-author of several publications and has two patents and four patents pending on AM technology. Singh was part of the winning team for SME’s Aubin AM Case Study Award in 2021.

About the company
DM3D Technology LLC is an additive 3D metal company that uses direct metal deposition (DMD) laser technology to form functional metal parts directly from 3D CAD data. Unlike other technologies such as laser sintering or binder jetting, DMD technology produces fully dense metal parts with a strong metallurgical bond to the base material, resulting in production parts. DM3D’s expertise and innovation, which is protected by its highly proprietary patents and trade secrets, gives the company its competitive advantage in the market.


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