Metelled – METal Evolved by Linear LasEr Deposition

"Metelled conceives a new method in additive manufacturing (AM) creating both new exploitation strategies and employment opportunities. It could offer a new avenue to the applicability and diversity that metal AM technology offers. New larger scale deposition, with micro features, optimal energy management and low cost production will be possible using the process.

The Metelled project uses atomic layer deposition to construct 3D structures. The rapid deposition process is used to produce kilo tonnes of high purity metals in other industries. Low temperature processing is possible because there is no melting of metal, therefore residual stresses are minimised, inclusions and porosity are eliminated.

The Metelled process consumes feedstock is lump metal instead of powders. All the components can be recycled within the equipment, and no expensive shielding gases are required or vented. This feasibility study constructs a deposition cell to study laser effects on linear deposition through glass.

The innovation arises because the process is:

* The lowest energy method to produce a metallic part from a raw ore.
* The deposition process is low energy and low temperature.
* Chamber build volumes can be large.
* Low residual stress may eliminate post-processing costs and energy.
* Easy to handle lump feedstock is used instead of powders.
* Quick change of feedstocks gives a plug-and-play approach.
* Fine resolution, from atomic level deposition.
* Wide area deposition also possible.
* Homogeneous X, Y, Z strength.
* Rapid z height deposition."