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LENS Deposition of Complex Geometries
The Laser Engineered Net Shaping (LENS®) system at Sandia National Laboratories, a
laser-based direct metal deposition process, was recently used for the fabrication of a complex
prototype. The LENS process involved the challenges of adjacent areas of thick and thin cross
section, overhanging unsupported features, high aspect ratios, and a hemispherical substrate.
These challenges were overcome through the use of closed-loop weld pool control, height
monitoring, a strong understanding of build parameters, and unique process planning strategies.
The near-net shape LENS part was completed with annealing and conventional machining to
produce the complex components in a reduced timeframe.Mechanical Engineerin