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<p>Directed Energy Deposition (DED) is a powerful metal additive manufacturing process, yet it frequently suffers from heat accumulation and unstable thermal cycles that lead to geometric distortion, excessive penetration, and heterogeneous microstructures. To address these limitations and avoid the restricted control of commercial systems, this study presents A Low-cost, Open-source Hardware Architecture for DED, referred to as ALOHA-DED. The platform provides full access to hardware signals and real-time actuation, enabling advanced sensing and adaptive control capabilities that are not feasible on proprietary machines. A non-contact off-axis pyrometer was integrated for continuous melt pool temperature monitoring, and a Proportional–Integral–Derivative controller implemented on Digital Signal Processor-based controller that leverages a Field-Programmable Gate Array for high-speed hardware acceleration. Experiments using stainless steel 316&#xa0;L powder demonstrated that the closed-loop thermal control effectively suppresses thermal runaway. During thin-wall fabrication, open-loop deposition exhibited a thermal drift greater than 300&#xa0;°C, whereas the closed-loop system maintained a stable melt pool temperature of 1800&#xa0;°C by automatically reducing laser power by approximately 40%. This resulted in a controlled conduction-mode melt pool, refined grain structure, and a 20–30% increase in micro-hardness. These findings confirm that pyrometry-based closed-loop thermal control substantially improves thermal stability and build quality in DED processes.</p>

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ALOHA-DED: A Low-cost Open-source Hardware Architecture for Directed Energy Deposition Enabling In-Situ Thermal Control and Enhanced Microstructural and Mechanical Performance

  • 期刊论文

  • 发表日期：

    2026年7月1日

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  • Mohammad Rezazadeh,
  • Ji-Won Lim,
  • Hong-Seok Kim,
  • Geon-Ju Kim,
  • Melkamu Tadesse Getachew,
  • Do-Sik Sim,
  • Sang-Hu Park

摘要

Directed Energy Deposition (DED) is a powerful metal additive manufacturing process, yet it frequently suffers from heat accumulation and unstable thermal cycles that lead to geometric distortion, excessive penetration, and heterogeneous microstructures. To address these limitations and avoid the restricted control of commercial systems, this study presents A Low-cost, Open-source Hardware Architecture for DED, referred to as ALOHA-DED. The platform provides full access to hardware signals and real-time actuation, enabling advanced sensing and adaptive control capabilities that are not feasible on proprietary machines. A non-contact off-axis pyrometer was integrated for continuous melt pool temperature monitoring, and a Proportional–Integral–Derivative controller implemented on Digital Signal Processor-based controller that leverages a Field-Programmable Gate Array for high-speed hardware acceleration. Experiments using stainless steel 316 L powder demonstrated that the closed-loop thermal control effectively suppresses thermal runaway. During thin-wall fabrication, open-loop deposition exhibited a thermal drift greater than 300 °C, whereas the closed-loop system maintained a stable melt pool temperature of 1800 °C by automatically reducing laser power by approximately 40%. This resulted in a controlled conduction-mode melt pool, refined grain structure, and a 20–30% increase in micro-hardness. These findings confirm that pyrometry-based closed-loop thermal control substantially improves thermal stability and build quality in DED processes.