Automated Process Planning for Additive Manufacturing with Directed Energy Deposition

This book provides an in-depth exploration of process planning steps required for Directed Energy Deposition (DED) processes and their automation during the data preparation stage. DED is a resource-efficient, tool-less manufacturing method with high deposition rates and larger build volumes. Their flexibility, enabled by 6-axis industrial robots, allows fabrication of complex geometries, but poses challenges in data preparation and build strategy definition due to software limitations and lack of standards. This thesis thereby deals with the development of a STEP file format-based slicing framework with toolpath generation algorithms specific to build geometries clustered under six categories. Thin-wall components cluster, an important part category in the aerospace sector, is being further examined because of its industrial relevance. The content - Comprehensive overview of the process chain of Directed Energy Deposition - Algorithms for slicing and toolpath generation of CAD data based on STEP-file format - Methodology for systematic identification of process parameters and build strategy The author Vishnuu Jothi Prakash’s journey began with a Bachelor of Engineering in Mechanical Engineering from PSG College of Technology in Coimbatore, India, graduating in 2013. Having gained industrial exposure at MAHLE Filter Systems in Gurgaon, India, he moved to Germany for a Master of Science in International Production Management at Hamburg University of Technology (TUHH), completing it in 2017. He then worked as a Research Associate at Laser Zentrum Nord GmbH in Hamburg on laser material processing projects. Since January 2018, he has been with Fraunhofer IAPT, focusing on advancing additive manufacturing through research and collaboration with industry partners.