FormAlloy Directed Energy Deposition Systems and Metal Manufacturing Services
FormAlloy Technologies, Inc. designs and builds DEDSmart® Directed Energy Deposition (DED) systems and provides metal additive manufacturing services from El Cajon, California. We help aerospace, defense, energy, and industrial manufacturers produce new metal parts, add features and coatings to existing ones, and repair worn or damaged components. DEDSmart® supports both powder and wire deposition, with real-time process monitoring and control.
As a full-service additive manufacturing company, FormAlloy Technologies provides DED systems and services, delivering precise additive printing metal and steel additive deposition for additive mfg, joining, and repair through its DEDSmart® Metallic Tech and proprietary alloy technologies.
FormAlloy DEDSmart Technology enables unique designs, producing high-quality, repeatable parts 2-100x faster with superior monitoring. It enhances products with multi-material features, wear-resistant coatings, and improved mechanical properties. It also repairs components with fully dense, metallurgically bonded layers, minimizing post-processing.
FormAlloy DEDSmart Technology creates precise, repeatable parts faster, enhances products with multi-material features, and repairs components with metallurgically bonded layers.
FORM
DEDSmart® builds metal parts layer by layer with features that conventional machining or casting can’t produce. Parts are produced 2–100x faster than other methods, with in-process monitoring for consistent, repeatable quality. Materials include IN718, IN625, Stellite 6, and copper.
Our DEDSmart® DED process creates high-quality, repeatable parts 2-100x faster than conventional methods with exceptional in-process monitoring and control.
Multi-Material Components
IN718
IN625
Copper Component
Laser Cladding Technology
FormAlloy’s DEDSmart® technology delivers precision, speed, and reliability. Real-time monitoring ensures quality when processing IN718, IN625, Stellite 6, and Copper + IN625 Clad for aerospace, industrial, and high-performance applications. Optimize designs, enhance efficiency, and achieve next-generation performance.
FormAlloy’s DEDSmart® technology ensures precision, speed, and reliability with real-time monitoring for consistent quality and next-generation performance.
ENHANCE
DEDSmart® adds new features and multiple materials to new or existing parts. Our cladding process creates fully dense, metallurgically bonded coatings that improve wear resistance, corrosion resistance, and high-temperature performance. For example, an IN625 cladding layer adds mechanical strength to a conductive copper part.
FormAlloy systems enhance products with multi-material features, improving strength, temperature resistance, and corrosion protection through metallurgically bonded coatings.
Advanced Metal Manufacturing Solutions
IN718
Additive Manufactured Door Handle
FormAlloy’s DEDSmart® technology enhances performance with advanced metal manufacturing solutions capabilities. Strengthen components, improve durability, and extend service life with metallurgically bonded coatings and multi-material solutions. Achieve superior wear, corrosion, and heat resistance for demanding applications.
FormAlloy’s DEDSmart® technology strengthens components, improves durability, and enhances wear, corrosion, and heat resistance with metallurgically bonded coatings and multi-material solutions.
REPAIR
DEDSmart® rebuilds worn or damaged areas on high-value components such as machine parts, dies, and molds. The process deposits fully dense, metallurgically bonded material in layers from microns thick and up, so repaired parts need minimal post-processing and return to service sooner.
FormAlloy’s DEDSmart® technology restores worn components with metallurgically bonded layers, enabling precise, durable repairs with minimal post-processing.
Repair Process
IN718
FormAlloy’s DEDSmart® technology restores damaged components with precision and strength. Achieve durable, metallurgically bonded repairs with minimal post-processing. Extend equipment life, reduce downtime, and enhance performance for critical applications.
Extend equipment life with FormAlloy’s precision repairs. Achieve durable, metallurgically bonded restoration with minimal downtime for critical applications.
FAQs
What does FormAlloy do?
FormAlloy Technologies, Inc. designs and builds DEDSmart® Directed Energy Deposition (DED) systems and provides metal additive manufacturing services. Based in El Cajon, California, the company helps manufacturers produce new metal parts, add features and coatings to existing parts, and repair worn or damaged components.
What is Directed Energy Deposition (DED)?
Directed Energy Deposition is a metal additive manufacturing process where a focused energy source, such as a laser, melts metal powder or wire as it is deposited. The material bonds to the part layer by layer. DED is used to build new parts, add features to existing parts, apply protective coatings, and repair damaged components.
Does FormAlloy provide DED systems and services?
Both. FormAlloy builds and sells DEDSmart® DED systems, and also offers in-house services including part production, repair, cladding, feasibility testing, and material development. Customers can start with a service project and later bring the technology in-house with their own system.
Which industries use FormAlloy technology?
FormAlloy works with aerospace, defense, energy, and industrial manufacturing companies. These industries use DED for high-value metal parts where speed, material performance, and the ability to repair components matter.
What materials can FormAlloy work with?
FormAlloy processes nickel superalloys such as IN718 and IN625, cobalt alloys such as Stellite 6, and copper, including copper parts clad with IN625. [Add other materials FormAlloy supports.]
Can FormAlloy repair damaged metal parts?
Yes. DEDSmart® rebuilds worn or damaged areas on machine components, dies, and molds by depositing fully dense, metallurgically bonded material. Layers can be as thin as microns, so repaired parts need minimal post-processing.
What makes FormAlloy different from other DED companies?
FormAlloy combines DED system manufacturing and production services in one company. DEDSmart® supports both powder and wire feedstock, includes real-time process monitoring and control, and handles production, enhancement, and repair on one platform. [Add a specific advantage, such as build volume, certifications, or number of patents.]
How fast is DED compared to other manufacturing methods?
FormAlloy’s DEDSmart® process produces parts 2–100x faster than conventional methods, depending on the part and material. Because DED adds material only where it is needed, it also reduces waste and machining time compared to cutting parts from solid metal.
What is laser cladding, and does FormAlloy offer it?
Laser cladding is a DED process that deposits a dense metal layer onto a part’s surface to improve wear, corrosion, or heat resistance. FormAlloy offers cladding with metallurgically bonded coatings, such as IN625 cladding on copper components for added mechanical strength.
What is the difference between DED and powder bed fusion?
Powder bed fusion builds parts inside a bed of metal powder and is best for small, highly detailed parts. DED deposits material directly where it is needed, so it is better suited for larger parts, repairs, adding features to existing parts, and combining multiple materials in one component.
Does FormAlloy offer metal 3D printing services?
Yes. FormAlloy provides metal additive manufacturing services, including part production, feasibility testing, material development, and repair. Customers can send part requirements to FormAlloy to evaluate whether DED is the right fit before committing to production.