Powder-based laser cladding is a versatile additive manufacturing process used particularly for coating components with functional or wear-resistant materials. Compared to conventional manufacturing processes such as milling or casting, laser cladding offers several advantages: It enables targeted material deposition only where functionally necessary, reduces material waste, and allows for high geometric flexibility.

Existing laser cladding systems limit the path width to 4 mm, requiring numerous paths to be applied side-by-side for the production or coating of large components. This is where the "BreitbahnDED" project comes in: The project is developing a novel prototype of a CNC-based laser cladding system. Using multi-spot optics, the temperature distribution will be optimized for the application of a pore-free, consistent layer thickness. The goal is to generate wide, uniformly thick weld paths with nearly the same energy input compared to conventional systems, thereby increasing process efficiency and minimizing the likelihood of defects.

The tasks of the Chair of Applied Laser Technologies include simulating temperature distribution using a rotating multispot optic. The Chair collaborates with project partners in the development, validation, and optimization of a prototype. For this purpose, it performs metallographic analysis of manufactured samples and characterizes them using light and scanning electron microscopy.

The Chair of Applied Laser Technologies is responsible for developing and implementing a control strategy for the new process. A further focus is on developing a layer-by-layer control system to enable near-net-shape manufacturing.