How multi-material DED printing works isn’t just something we talk about in theory—it’s something we’ve seen change everything.
On Tuesday, one of our aerospace clients in Ohio had a big problem. A rare copper-steel turbine blade cracked during stress testing, and they didn’t have a spare.
Making a new one using the old method would take weeks. Every day lost would mean serious money.
They called us.
We scanned the broken part, rebuilt the steel edge, and then reformed the copper base layer by layer with a strong, metallurgical bond. There was no gluing or welding, just clean, solid printing.
The part was back up and running the same day.
That’s what we mean when we talk about how multi-material DED printing works. It’s fast, strong, repeatable, and doesn’t waste materials.
We didn’t just fix the part. We helped them avoid downtime, avoid waste, and get back in the air without waiting on long lead times or costly machining.
So now we ask: what else can we fix? What else can we build? What materials can we combine?
While others are still stuck with slow, single-material repairs, we’re proving that the future is already here—and it prints in more than one material.
1. Fixing the Unfixable: New Ways to Repair Airplane Parts
Broken Parts? Throw Them Away? Not Anymore.
Airplane engines are tough, but parts can still crack or wear out. Fixing them usually takes a long time. But with multi-material DED printing, we can do it quickly.
Instead of replacing the whole part, DED adds new metal only where needed. It’s like giving the part a new skin, matching the original strength.
🔍 According to Ian Wright (Engineering.com, March 2025), here’s how DED helps:
- Repairs titanium and Inconel parts, common in airplanes.
- Less stress than traditional welding.
- Fixed parts are as strong as new ones.
- Very precise repairs, within 0.03mm
DED doesn’t just fix it—it upgrades. And fast.
Smart Repairs
- Adds different metals where needed.
- Rebuilds broken parts quickly.
- No weak spots or cracks.
Where It’s Used:
- Jet engines with copper-cobalt shields.
- Aluminum parts strengthened with titanium.
- Electric car motors with built-in cooling.
When time is critical, DED gets machines back to work fast.
2. Combining Strength & Conductivity
Why Not Have Both?
Copper is great at conducting heat, and inconel is super strong. But combining them has been difficult—until now.
🔬 Marques et al. (2022) showed that printing parts with both metals is possible. The result?
- Inconel hardness: 344 HV.
- Copper hardness: 126 HV.
- No cracks or defects.
- Each metal keeps its properties.
So, How Does DED Make It Work?
✅ Multi-powder integration for hybrid properties
- Thermal conductivity + structural load in one part
- Precise transitions during the build
- No post-process joining
✅ Seamless, functional interfaces
- Single-step fusion
- No bolts, brazing, or solder
- Heat and force flow uninterrupted
Common Material Combos:
- Copper + Inconel
- Stellite + Titanium
- Stainless Steel + Aluminum
That’s how multi-material DED printing works. It allows us to create parts that are both strong and efficient.
3. Rebuilding Old Parts Without Blueprints
Lost Designs? No Problem
Sometimes, we must fix old parts, but the original designs are missing. DED printing can help.
🔬 Li, Zhang, and Li (2024) showed how to repair aluminum parts using a robot arm and DED. They:
- Scanned the broken part.
- Rebuilt the missing sections.
- Added new metal where needed.
- Smoothed the surface.
- Tested the strength—it was strong.
Why This Matters
- No need for original blueprints.
- Can add better materials during repair.
- Fixes are precise, within 50 microns.
Benefits for Factories
📌 What’s in it for the floor manager?
- Less waste.
- Longer-lasting machines.
- Quickly make new metal parts.
A multi-muterial DED printing brings old parts back to life, even without original plans.
4. Fighting Rust with Lasers
Rust and Wear? Not Anymore.
Machines in salty or acidic places (like ships or mines) often rust. Traditional coatings can peel off. A multi-material DED printing offers a better solution.
🔬 Wang et al. (2024) showed that laser-cladded coatings on steel parts:
- Had high hardness (up to 821.8 HV).
- Resisted corrosion in saltwater.
- Wore down less than traditional coatings.
DED Advantages
✅ No flaking, no peeling
- 100% bonding at melt pool
- Zero porosity
- Lifetime coatings
✅ Material-by-zone deposition
- Copper base + Stellite 6 surface
- High-temp strength where needed
- Conductivity retained elsewhere
DED vs. Other Metal 3D Printing Technologies
📌 Why Is DED better?
- Works on existing parts
- Faster deposition rates
- Greater material variety
That’s how multi-material DED printing protects machines from rust and wear, keeping them running longer.
5. Futureproofing the Factory Floor
Too Much Inventory? DED Can Help.
Factories often have too many spare parts. DED printing lets them make parts only when needed.
🔬 Khanna et al. (2024), in their study titled Cost Modeling for Powder Bed Fusion and Directed Energy Deposition Additive Manufacturing, found that DED:
- Uses materials efficiently.
- Saves energy.
- Reduces production time.
Smart Manufacturing:
- Combine multiple parts into one.
- Fewer seals and connections mean fewer leaks.
- Control printing parameters in real time.
Optimizing DED Processes
- Adjust laser settings for different metals.
- Use custom printing patterns.
- Monitor temperature during printing.
What’s Next in DED
- Embed smart sensors during printing.
- Use AI to control printing paths.
- Switch materials during a single print.
DED Advancements in 2025
- Faster printing speeds (up to 1 kg/hr).
- High-resolution printing (under 50 microns).
- Robotic arms for complex shapes.
DED printing makes factories more efficient and ready for the future.
So… What’s Stopping You?
Engineers once dreamed of multi-material parts. Now, they can print them in one go, without waste or waiting.
Still wondering how multi-material DED printing works? The real question: Why are others still waiting on castings and welders?
FormAlloy doesn’t sell machines. It sells freedom from broken parts, static designs, and wasted stock.
So, are you printing legacy, or are you printing legacy parts?
👉 Are you ready to step into the future of functional parts?
FormAlloy’s DEDSmart® system is the only choice for serious manufacturers. Contact us today and print something that lasts.
