Abstract

The Laser Net Engineered Shaping (LENS) machine uses a Direct Layer Deposition (DLD) additive manufacturing method to create metallic alloy components and libraries in the Flores Lab. This DLD process uses nozzles to blow metallic powders into a melt pool created by a laser. Much of this powder gets wasted due to the small diameter of the melt pool and large area of the powder blown. By changing several processing variables, in this case the nozzle distance from the laser focus (Z-offset) and mass flow rate of the powder (RPMS). It was found a larger dot diameter correlated with an increase in the RPMs, leading to 2 RPMS being the most optimal to decrease dot diameter. There was no correlation observed between dot size and the theoretical mass deposition. These results are useful as they can be used to decrease the amount of powder used and thus save on cost while being environmentally friendly.

Document Type

Final Report

Author's School

McKelvey School of Engineering

Author's Department

Mechanical Engineering and Materials Science

Class Name

Mechanical Engineering and Material Sciences Independent Study

Language

English (en)

Date of Submission

5-26-2026

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