Why Multi-Laser Wire DED Is Gaining Attention in Metal Additive Manufacturing

As manufacturers push for higher deposition rates in Wire Laser Directed Energy Deposition (Wire DED), increasing laser power isn’t always the best solution. Higher power can lead to keyhole formation, excessive vaporization, spatter, and unstable melt pools.

This is why multi-laser systems are becoming increasingly important. By arranging multiple lower-power lasers around the wire, energy is distributed more uniformly, resulting in a more stable melt pool and better process control while maintaining high productivity.

But designing a multi-laser setup isn’t straightforward. Parameters such as beam angle, focal position, spot size, and power distribution all influence the final build quality.

With the latest AM PravaH® multi-laser capability, engineers can simulate N-laser Wire DED configurations, analyze melt pool behavior, and optimize process parameters before conducting physical trials. This helps reduce experimentation time while providing deeper insights into laser-material interaction.

As Wire DED continues to evolve, simulation is becoming an essential part of developing faster, more reliable, and more efficient manufacturing processes.