For decades, manufacturers have trusted castings and forgings. These processes have been around forever. They’re familiar. And they’re proven—well, sort of.
Here’s the thing: When you cast a metal part, it’s a bit of a mystery inside. You can inspect the surface. You can X-ray it. You can even slice it open. But you don’t know what’s going on in every layer, every second, during the build.
Now think of Directed Energy Deposition (DED), a modern metal additive manufacturing process. It’s precise. It’s smart. And, most importantly, it’s transparent. You can see what’s happening as it happens. Every single moment is tracked.
So, why are 3D-printed metal parts still harder to qualify than cast ones?
That’s what Melanie Lang, CEO of FormAlloy, wants to change.
Quote That Started the Conversation
“An additively manufactured part should be easier to qualify than a casting.”
– Melanie Lang, CEO, FormAlloy
That’s not just a bold statement. It’s a challenge to the industry.
Melanie isn’t saying we should accept lower standards. She’s saying we should accept better information. Because with DED, we’re not guessing—we’re watching, measuring, and recording.
And that’s exactly how modern manufacturing should work.
How DED Makes Better Parts—And Better Data
Let’s break this down like a chocolate cake recipe (but with lasers and metal).
DED builds metal parts layer by layer using a laser and metal powder or wire. Unlike casting, it doesn’t involve molds or cooling baths. You’re not pouring molten metal and hoping it cools evenly. You’re controlling every drop, every degree, and every step.
Now add real-time process monitoring.
That means sensors and cameras are watching when we build the part. They check temperature, power, melt pool size, and material flow.
Then layer on digital traceability.
That means you have a record of every layer, every second of the build, forever.
Finally, add precision control.
You can tweak power, speed, and material rate—all while the build is happening.
Try getting that kind of visibility from a casting. Spoiler: You can’t.
Why Castings Still Get a Free Pass
So, if DED is so good, why are people still more comfortable with castings?
Simple answer: habits.
The casting process has been around for centuries. Standards and certifications are built around it. It’s familiar. It feels safe.
But here’s the thing: familiarity doesn’t equal quality.
You can’t monitor a casting in real time. You don’t know the exact cooling rate inside that mold. And you can’t trace every part of the process.
DED gives you more data, more control, and more confidence.
So, shouldn’t we trust it more, not less?
The Role of Certification and Qualification in AM
In the world of manufacturing, part qualification means proving that a part meets all design, safety, and performance requirements.
With additive manufacturing, especially metal AM, this gets tricky. Why? Because the standards were not for it.
That’s slowly changing. But until then, additive parts are often judged by old rules.
At FormAlloy, we believe that DED deserves its rulebook, one based on data, not assumptions.
We’re not saying “trust us.” We’re saying, “Look at the numbers.”
How FormAlloy Makes AM More Qualifiable
At FormAlloy, we’ve built DEDsmart systems with smart monitoring baked in. It’s not an extra feature. It’s part of the machine’s DNA.
Our systems collect data in real time. They let you see the process from start to finish. You get a full traceable build history, down to every single layer.
That’s what makes our additive parts easier to qualify. Not just because they’re better, but because we can prove it.
Want to see how we do it? 👉 Check out the FormAlloy blog for deep dives into DED systems, monitoring tools, and real customer results.
Quality, Not Just for Quality’s Sake
Better quality isn’t just a checkbox.
It means parts last longer. It means fewer failures. It means safer flights, stronger machines, and lower costs.
And most importantly, it means trust.
Trust in the process. Trust in the data. And trust in the part.
That’s what we’re building at FormAlloy. One qualified part at a time.
Final Thoughts: Don’t Guess—Know
Castings and forgings had their time. They helped us build the modern world. But they’re black boxes—hard to inspect, harder to trace.
Additive manufacturing, especially DED, opens that box. It gives you control, visibility, and a digital trail you can follow from start to finish.
So, let’s stop acting like an additive is the new kid that needs to prove itself. It’s smarter. It’s better. And it’s ready.
And at FormAlloy, we’re leading the way with DED systems that make parts easier to qualify, not harder. Contact us now.
FAQs: Additive Qualification, DED, and Why It Matters
- What is part qualification in additive manufacturing?
Part qualification means proving that a part meets all the design, strength, and performance standards for which it was built.
- Why are additively manufactured parts harder to certify?
Because the rules were written for castings and forgings. Additive parts often face stricter reviews—even if they’re built more precisely.
- How does FormAlloy make parts easier to qualify?
FormAlloy uses real-time monitoring, data capture, and full traceability so you can prove part quality at every layer.
- What is Directed Energy Deposition (DED)?
DED is a metal 3D printing process that builds parts by melting metal powder or wire with a laser, one layer at a time.
- Can DED repair existing parts?
Yes! DED is often used to repair or rebuild expensive parts like turbine blades or molds.
- What kind of data does FormAlloy capture?
We track laser power, temperature, material flow, and more, so every part has a digital history.
- How does this compare to casting?
Casting offers very little real-time data. With DED, you know exactly what happened during every second of the build.
- What industries use DED?
Aerospace, energy, defense, automotive, and more. Anywhere that strong, high-performance metal parts are needed.
- Can I test my parts at FormAlloy’s Application Development Center?
Yes! We offer development, testing, and hands-on support at our dedicated facility.
- Where can I learn more about FormAlloy’s tech?
Start here 👉 FormAlloy Blog for articles, insights, and updates straight from our team.
