Process Planning for Additive Manufacturing of Geometries with Variable Overhang Angles Using a Robotic Laser Directed Energy Deposition System

In the present work, a novel Laser Directed Energy Deposition (LDED) process planning methodology is proposed to build a dome structure with variable overhang angles. Overhang structures with different overhang angles were built where the maximum angle of 35° can be used to build overhang structures without the process and structure compromise. The thin-wall hemisphere dome built using the developed methodology shows a maximum deviation of 2 mm between the original model and the fabricated artifact. The study paves a way for building high-value, lightweight thin-walled structures with complex cylindrical-based shape (e.g., storage tanks, nozzles, combustion chambers) for engineering applications