On the first episode of our video series “AM: Why the Failure?” to deal with directed energy deposition (DED), Penn State professor of additive manufacturing Tim Simpson and I discuss a component intended to be a nozzle that developed a crown-like form during 3D printing. The part accidentally came to resemble a chess piece. What was the cause of this error?
Guesses in social media focused on software or programmed motion paths, but the true cause was thermodynamics. Heat was not able to escape the part fast enough. The melt pool therefore grew too large at the six different start points around the part’s various circular layers, producing six different high points. Tim discusses some of the remedies for this problem.
This episode brought to you by Verisurf. www.verisurf.com/  
Related resources:
- LinkedIn post about this part, with guesses about the cause of the crown: www.linkedin.com/posts/peterzelinski_amwtf-activity-6788481185363353600-aGQg
- About DED: www.additivemanufacturing.media/articles/what-is-directed-energy-deposition(2)
- Important uses of DED: www.additivemanufacturing.med...
- DED for cylindrical parts: www.additivemanufacturing.media/articles/video-programming-for-additive-turning-of-cylindrical-parts
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