3D Printing
News Videos Newsletter Contact us
Home / News / Researchers Use Digital Twin for DED Optimization
revopoint

Researchers Use Digital Twin for DED Optimization

January 29, 2023

A group of researchers from Tokyo University of Science and Suwa University of Science, in Japan, have collaborated with TOCALO Co. Ltd. to optimize laser Directed Energy Deposition (DED) with the use of a digital twin.

DED + Digital Twin

The DED process melts the metal particles and fuses them to build up a 3D object, much like typical metal printing, except with a DED process, it does not require a print bed. The melt pool can be manipulated over curved geometries outside of a build chamber, meaning it can be used to repair metal components in situ by depositing metal powders on the surface to be repaired.

DED offers advantages over other 3D printing techniques as it can produce more compact equipment and reduce metal powder waste. However, until now it has largely been difficult to optimize, requiring a large amount of trial and error to get the best results.

To reduce the amount of guesswork needed for the process, the researchers developed a digital twin of the core machining technology based on the fusion of metal in the area to be repaired.

3D numerical analysis of DED process
3D numerical analysis of DED process (Image credit: Tokyo University of Science)

This digital twin was effectively a 3D machining numerical analysis system that made use of a mathematical model of the DED process, and automatically generated a metal powder deposition region with a death-birth algorithm. The system was able to apply the thermal radiation, thermal conduction and viscoplastic/thermoplastic constitutive models to the deposited region, allowing for accurate simulation of the entire state change process from melting to solidification.

A death-birth algorithm is a type of optimization algorithm that iteratively adds or removes elements from the solution set to find the optimal solution. In the context of DED, the death-birth algorithm is used to generate the metal powder deposition region that results in the best repair outcome. The algorithm eliminates the need for trial and error, and instead finds the optimal conditions for the repair process automatically.

Optimized

By incorporating these models into a finite element analysis program, the team was able to predict the forming process conditions, temperature distribution, deformation state, and residual stress distribution in advance, which was then verified through experiments.

Overall, the researchers demonstrated that DED is superior to other repair methods in terms of interfacial strength, with lower residual stresses in the deposited layer, and other improved mechanical properties.

FEA-enabled digital twin.
DED made more efficient with FEA-enabled digital twin. (Image credit: Tokyo University of Science)

“Using our technique, the surface shape of a metal structure can be completely restored on-site, and the disposal of the metal powder required for repair can be significantly reduced,” said Professor Masayuki Arai, Tokyo University of Science.

“However, the optimum forming conditions required for the widespread application of this technology in industry had to be hitherto determined by a trial-and-error process.”

This digital twin has the potential for various industrial applications, such as repairing cavitation thinning on power plant blades, and reducing residual deformation after repairing thinning on gas turbine rotor blades. With its automation and prediction capabilities, the numerical machining analysis system makes DED repair technology more efficient and sustainable.

Share:
WhatsApp Twitter Facebook LinkedIn Buffer Reddit E-mail
About the author | Phillip Keane
Phillip is an aerospace engineer from UK. He is a graduate of Coventry University (UK), International Space University (France) and Nanyang Technological University (Singapore), where he studied Advanced Manufacturing at the Singapore Centre for 3D Printing.
Join our newsletter

Our newsletter is free & you can unsubscribe any time.

Latest posts

New 3D-Printing Technique Creates Dual-Material Objects from Single Resin

Researchers have developed a new Vat photopolymerization technique that creates both permanent objects and dissolvable supports in a single process. According to a... read more »

Materials
New 3D-Printing Technique Creates Dual-Material Objects from Single Resin

Northumbria Receives EU Funding for Sustainable 3D-Printed Construction Research

Northumbria University has received a Marie Skłodowska-Curie Actions (MSCA) Fellowship worth over a quarter million euros to research low-carbon, 3D-printed construction materials. The... read more »

Construction
Northumbria Receives EU Funding for Sustainable 3D-Printed Construction Research

3D-Printed Sports Bra Could Help Olympic Star Break Historic Athletics Record

Nike has developed a new 3D-printed sports bra called the FlyWeb Bra for runner Faith Kipyegon's attempt to break the 4-minute mile barrier.... read more »

News
3D-Printed Sports Bra Could Help Olympic Star Break Historic Athletics Record

Vietnam Emerges in High-Tech Medicine as Vinmec Pioneers 3D-Printed Breakthroughs

Across pediatric, adult, and geriatric cases, Vietnam’s Vinmec Healthcare System's implementation of 3D printing solutions has significantly transformed patient outcomes, replacing disability with... read more »

Medical
Vietnam Emerges in High-Tech Medicine as Vinmec Pioneers 3D-Printed Breakthroughs

Johns Hopkins APL Helps Navy Overcome Metal 3D Printing Reliability Concerns

Researchers at the Johns Hopkins Applied Physics Laboratory (APL) are working with the Naval Sea Systems Command (NAVSEA) to address reliability concerns with... read more »

3D Printing Metal
Johns Hopkins APL Helps Navy Overcome Metal 3D Printing Reliability Concerns

New 3D Printing Technique Creates Glass Objects at Low Temperatures

Researchers at MIT Lincoln Laboratory have developed a new low-temperature process for 3D printing glass objects. This method creates complex glass structures without... read more »

News
New 3D Printing Technique Creates Glass Objects at Low Temperatures

Farsoon Launches High-Volume Copper Alloy 3D Printing System FS621M-Cu

Farsoon has developed a specialized 3D printing system for producing large copper alloy components for aerospace applications. The company's new FS621M-Cu system, built... read more »

3D Printing Metal
Farsoon Launches High-Volume Copper Alloy 3D Printing System FS621M-Cu

Pratt & Whitney Tests 3D Printed Rotating Part for TJ150 Engine

Pratt & Whitney has completed a series of tests on its 3D printed TJ150 turbine wheel. The company, an RTX business, reports the... read more »

Aerospace
Pratt & Whitney Tests 3D Printed Rotating Part for TJ150 Engine

University of Bristol Researchers are Testing 3D-Printed Structures for Earthquake Resistance

University of Bristol researchers are testing 3D-printed structures for earthquake resistance using a specialized shaking table. The experiment, conducted at the university's Soil... read more »

Construction
University of Bristol Researchers are Testing 3D-Printed Structures for Earthquake Resistance

3D Printing Technology Tested on Historic Bridge in Great Barrington as Potential Solution for Aging Infrastructure

Researchers from UMass Amherst and MIT have successfully applied 3D printing technology to repair a bridge in Great Barrington, Massachusetts. The test utilized... read more »

3D Printing Metal
3D Printing Technology Tested on Historic Bridge in Great Barrington as Potential Solution for Aging Infrastructure

Social

  • Facebook Facebook 3D Printing
  • Linkedin Linkedin 3D Printing
Join our newsletter

Our newsletter is free & you can unsubscribe any time.

Featured Industries

  • Automotive
  • Aerospace
  • Construction
  • Dental
  • Environmental
  • Electronics
  • Fashion
  • Medical
  • Military
  • QIDI Plus4

    • - Print size: 305 x 305 x 280 mm
    • - print temperature of 370°C
    More details »
    $799.00 QIDI Store
    Buy Now
  • QIDI Tech X-Max 3

    • - Print size: 325 x 325 x 315 mm
    • - fully enclosed
    More details »
    $799.00 QIDI Store
    Buy Now
  • Snapmaker Artisan Premium 3-in-1

    • - Print size: 400 x 400 x 400 mm
    • - comes with enclosure
    More details »
    $2,999.00 Snapmaker
    Buy Now
  • QIDI Tech Q1 Pro

    • - Print size: 245 x 245 x 245 mm
    • - 600mm/s max speed
    More details »
    $449.00 QIDI Store
    Buy Now

Company Information

  • What is 3D Printing?
  • Contact us
  • Join our mailing list
  • Advertise with us
  • Media Kit
  • Nederland 3D Printing

Blog

  • Latest News
  • Use Cases
  • Reviews
  • 3D Printers
  • 3D Printing Metal

Featured Reviews

  • Anycubic Photon Mono M5s
  • Creality Ender 5 S1
  • The Mole 3D Scanner
  • Flashforge Creator 3 Pro

Featured Industries

  • Automotive
  • Aerospace
  • Construction
  • Dental
  • Environmental
  • Electronics
  • Medical
  • Military
  • Fashion
  • Art
2025 — Strikwerda en Dehue
  • Home
  • Join our mailing list
  • Contact us
Blog
  • Latest News
  • Use Cases
  • Reviews
  • 3D Printers
  • 3D Printing Metal
Featured Industries
  • Automotive
  • Aerospace
  • Construction
  • Dental
  • Environmental
  • Electronics
  • Medical
  • Military
  • Fashion
  • Art
Company Information
  • What is 3D Printing?
  • Contact us
  • Join our mailing list
  • Advertise with us
  • Media Kit
  • Nederland 3D Printing