FastWireAM: Fast-track development of a novel compact wire-feed system for Laser Additive Manufacturing

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COVID-19 has caused significant disruption to many markets and has created a need for flexible and adaptable manufacturing methods that can offer significant economic advantages to cope with the disruption. Additive manufacturing (AM) is an obvious candidate that has already seen some industrial success especially in the aerospace, medical and power generation sectors due to its high process efficiency, low material wastage, and the ability to manufacture components or coatings with complex geometries and/or improved material properties.The compact wire-feed head developed by HMT for wire laser metal deposition (w-LMD), a form of AM, has the potential to supersede both traditional subtractive manufacturing methods as well as current state-of-the-art AM processes. The head is capable of depositing material between 0.5 -- 4+kg/hr and was developed from standard w-LMD side-feed technology. However, its unique design allows for a more stable process with effective-omnidirectional deposition. The head is also very adaptable due to its compact size, where its laser - blown powder variant is globally leading in its design for ease of integration into machine tools though automated tool change system.This project will develop and deploy an innovate approach for wire delivery in LMD to prove the commercial viability in a number of different industrial sectors. This will be achieved by applying the technology to a number of real-world industrial components to demonstrate added-value and market potential within the UK.The key outputs from _FastWireAM_ are:1\.**Demonstration of added-value** provided by the w-LMD head, including reduced production time and material waste, accelerating **market uptake** in a number of diverse sectors and applications to provide additional revenue streams for the partners.2\.**Improved hardware and process** through performance mapping and parameter optimisation, ensuring a robust and reliable manufacturing method and quality required by industry.The successful completion of this project will demonstrate and establish the commercial viability of this process. We expect that the technology will be offered as a manufacturing solution to both current and new customers and revenue streams, and retrofitted onto new and existing machine tools.