Hybrid Directed Energy Deposition of Geometrically-Complex Pressure Vessels for Advanced HIP Canning and Digitally-Driven Powder Metallurgy

Directed Energy Deposition (DED) is one of the highest production rate additive manufacturing processes, yet it often faces challenges with dimensional accuracy and surface finish compared to powder bed fusion. Fabricating structures with internal cavities using DED is typically constrained unless a five axis motion system is employed, allowing for the maintenance of a normal to gravity orientation during deposition, which is essential for creating overhanging features and completing enclosed cavities. This capability is particularly valuable for applications sich as pressure vessels and geometrically complex hot isostatic pressing (HIP) containers. The present work explores the tool path strategy required to construct a toroidal cylinder with an internal cavity. Leak testing and cross-sectional analysis such as optical microscopy and the Archimedes density test, confirm that the structure is sufficiently pressure’tight and exhibits minimal porosity, making it suitable for use as complex HIP can, thus paving the way for the next generation of multi-material, digitally-driven powder metallurgy.