Advancing manufacturing through automation – Aerospace Manufacturing and Design

About the presentation

This presentation focuses on large metal part additive manufacturing with newly developed multi-nozzle directed energy deposition (DED) manufacturing technology. Recent advances in technology now make large part printing economically feasible and technically superior. The presentation showcases the additive manufacturing of NASA’s RS-25 engine nozzle liner. This part is 111″ tall, has a 96″ base diameter, and weighs about 4,100 lbs. The build approach of this liner is discussed to highlight various challenges to large part printing and strategies adopted to mitigate these challenges. The goal of the presentation is to bring awareness to the advancement of metal additive manufacturing (AM). This is achieved by demonstrating the ability to print large complex parts with difficult materials while targeting critical industry applications. At the same time, the presentation aims to educate attendees of the various challenges presented by large-scale printing, and how industry partners are working together to solve these problems. Last but not the least, the presentation shows how various industry teams came together with government agencies to advance existing technologies and develop new ones to solve difficult manufacturing challenges and advance metal AM 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; improving part quality; and developing a stable, competent workforce to lower 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 more than 30 years of experience in the field of metallurgy and metal processing, including 17 years in the AM industry. He has multiple technical publications and presentations in the field of AM, as well as two co-authored books and several book chapters. He also has five patents and five pending patents on metal AM. He is a member of ASM International and AMPM Program Committee. Bhaskar was on the winning team for SME’s Aubin AM Case Study Award in 2021.

Farhad Ghadamli is the lead AM engineer at DM3D Technology. During his professional career, he worked with different 3D printing equipment manufacturers as well as Eaton Polymer and Nanocomposite group and 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 has a Master and Bachelor of science in mechanical engineering from the University of California, Davis. In 2021, he was one of the recipients of the SME’s Aubin AM Case Study Award as well as SME President’s award for his work as the chair of Metro Detroit SME. He was recognized as one of 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 co-authored multiple publications and has three patents and two pending patents 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 production AM work. He has 41 years of industry experience including 15 years in AM. Prior to DM3D, Fortuna worked in various industries including laser welding machine building and laser welded filter assembly. Fortuna was on 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 design and building of DMD Systems. Singh has a Master of Electrical Engineering with 26 years of controls engineering experience. His fields of expertise include Metal 3D Printing, Laser, CNC & Robotic processes. He co-authored multiple publications and has two patents and four pending patents on AM technology. Singh was on the winning team for SME’s Aubin AM Case Study Award in 2021.

About the company
DM3D Technology LLC is an additive metal 3D company that uses laser based direct metal deposition technology (DMD) 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 patents and highly proprietary trade secrets, give the company its competitive edge in the marketplace.

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