The word “manufacturing” might still bring up images of smoke stacks, conveyor belts, and rooms filled with machines older than your favorite uncle. But walk into FormAlloy’s Application Development Center today, and that picture flips fast.
No smoke. No noise. Just clean, focused energy.
A laser dances across a metal part. A robot adjusts its path. A screen shows real-time data. And a team of engineers watches a new future take shape.
It isn’t just another machine shop. It’s where metal gets a brain, and additive manufacturing gets serious. It is where ideas turn into tools, blades, nozzles, housings, and new ways of thinking.
FormAlloy doesn’t just build metal 3D printers. We build the tools that build what’s next.
Innovation Isn’t a Buzzword. It’s What’s Happening Right Now.
Every day, our center runs at full speed. Customers visit to test new parts. Partners join us to explore new alloys and designs. And our systems keep pushing boundaries that most people don’t even know exist yet.
From automated part repair to robotic large-format builds, what we’re doing today felt impossible a few years ago. Now, it’s just part of the job.
DED is the engine. But what we’re building is performance, precision, and flexibility in every layer.
Functionally Graded Materials. Sounds Fancy. Works Smarter.
Want a metal part that’s tough on the outside and soft inside? Or one that changes material mid-build? Welcome to functionally graded materials (FGMs).
With our powder + wire-fed DED systems, you can change materials as you build. Imagine printing a part with copper on one side and Inconel on the other—on purpose.
It isn’t magic. It’s multi-material additive manufacturing. And it opens up whole new possibilities for design and performance.
Automated Repair: Fix It Before You Toss It
Every broken part doesn’t need to be replaced. That’s an old way of thinking, and a wasteful one.
With FormAlloy’s automated scanning, toolpath generation, and closed-loop monitoring, we can repair parts like turbine blades, valves, or tools quickly and accurately.
You don’t need to wait weeks for a new part. You can scan it, fix it, and fly (or drill, or cut) again. And yes, our DED systems know how to do it automatically. No guesswork. No delays.
Robots and Lasers? Yes, Please
Big parts need big tools. That’s where robotic integration comes in.
Our systems can be integrated with robot arms to build large-format parts for aerospace, defense, energy, and more.
You get motion, reach, and precision—all working together. Robots move. Lasers melt. Sensors monitor. And huge parts get made with stunning accuracy.
It isn’t science fiction. It’s happening in the FormAlloy Application Development Center right now.
Performance at Scale: R&D Today, Production Tomorrow
Innovation doesn’t matter if you can’t scale it. That’s why FormAlloy systems are built for both R&D and full-scale production.
You can start with a single system to test a material. Then scale to a full line with automated controls, monitoring, and multi-axis capabilities.
Need custom alloy development? Need small batch repair? Need mass production with full part traceability?
Yes, yes, and yes. FormAlloy delivers flexibility now, and scalability later.
What Makes FormAlloy Different?
Here’s what you’ll find under the hood:
✅ Powder + Wire DED: Flexibility to build complex parts and switch materials
✅ In-Situ Monitoring: Know what’s happening during every second of every build
✅ Closed-Loop Control: Adjusts automatically for perfect layers every time
✅ Automated Toolpaths: Repairs and builds are faster, smarter, and more reliable
✅ Scalability: From one machine to full-scale factory production
FormAlloy is where cutting-edge tech meets real-world results. And we’re proud to support aerospace, energy, defense, and manufacturers building what’s next.
Want to learn more about the systems behind the sparks? Visit the FormAlloy blog for more stories and solutions.
Final Thoughts: Don’t Just Keep Up. Leap Ahead.
The world is changing fast. Designs are more complex. Timelines are shorter. And materials are evolving.
You can’t wait for old processes to catch up. You need tools that think, adapt, and build smarter.
FormAlloy doesn’t offer one-size-fits-all machines. We offer systems that grow with you. We offer support that moves at the speed of your ideas. And we offer a team that’s as excited about the future as you are.
So, let’s build that future—one smart, shiny, laser-melted layer at a time.
👉 Looking to modernize your manufacturing process? Let’s talk.
FAQs: Additive, Automation, and the FormAlloy Advantage
- What is Directed Energy Deposition (DED)?
DED is a type of metal 3D printing that uses a laser to melt metal powder or wire and build parts layer by layer.
- What are functionally graded materials?
They’re parts made from multiple materials that change across the part for better performance in different areas.
- Can FormAlloy systems repair parts?
Yes. Our systems can scan damaged parts and automatically generate toolpaths to repair them with metal.
- What’s the benefit of powder + wire DED?
It gives you flexibility. Use powder for precision. Use wire for high-volume builds. Or combine both.
- Is robotic integration hard to set up?
Not at all. We support full robotic integration for building large-format metal parts with multi-axis motion.
- What industries use FormAlloy systems?
Aerospace, energy, defense, and heavy industry—all benefit from DED’s speed, control, and part quality.
- Can I develop custom materials with FormAlloy?
Yes. We help customers explore new materials and functional designs, especially with our powder + wire system.
- Do you offer R&D and production systems?
Yes. You can start with small-scale development and scale to high-volume production on the same tech stack.
- How does closed-loop control help?
It adjusts the build process automatically in real time to make sure each layer is perfect, even if something changes.
- How do I get started with FormAlloy?
Easy. Visit formalloy.com or contact us to set up a visit to our Application Development Center.
