Laser DED additive manufacturing – Fluid ejector sleeve (large hybrid part)

The aim is to produce a large part (Ø 600 mm) incorporating complex internal channels that cannot be machined in a one-piece structure. The solution must ensure efficient fluid guidance with stringent requirements for pressure losses and surface finish, while reducing the costs and lead times of a 100 % PBF approach limited by support structures and part size.

IREPA LASER implements a hybrid approach combining PBF to manufacture the body of the part, including the internal channels, with powder-based laser DED for the rapid addition of external features (nozzles, collars). This strategy takes advantage of the geometric freedom of PBF and the deposition rate of DED within an integrated, optimised manufacturing chain.

Success depends on consistent design and segmentation between the two processes, taking into account from the outset the manufacturing constraints of the non-remachinable internal channels and the functional interfaces. It is also a matter of mastering PBF/DED hybridisation without breaking industrial continuity, while optimising manufacturing times on a large part.

The resulting hybrid part integrates complex internal features and add-on elements produced efficiently by DED. This demonstration validates the value of process hybridisation as a lever for reducing costs and lead times, while ensuring the functional performance and industrial feasibility of large, complex parts.