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A Generic Geometric Code-Parsing Framework for Corner Optimization in Curved-Surface Directed Energy Deposition.

Lan Jiang1, Zhongkai Li1, Xiaofang Pan1

  • 1School of Materials Science and Engineering, Central South University, Changsha 410083, China.

Materials (Basel, Switzerland)
|February 27, 2026
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Summary
This summary is machine-generated.

This study introduces a path-optimization strategy to prevent defects in laser-cladding directed energy deposition on curved surfaces. The method improves dimensional accuracy and surface quality for industrial-scale additive manufacturing.

Keywords:
additive manufacturingcomplex curved surface partsdirected energy depositionpath optimization

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Area of Science:

  • Additive Manufacturing
  • Materials Science
  • Mechanical Engineering

Background:

  • Laser-cladding directed energy deposition (LC-DED) is used for repairing and fabricating complex metallic parts.
  • Multi-axis deposition on curved substrates often results in over-deposition and geometric defects at corners due to feed-rate fluctuations.
  • These defects hinder surface-profile fidelity and limit practical applications.

Purpose of the Study:

  • To develop a novel strategy for optimizing toolpaths in curved-surface LC-DED.
  • To mitigate over-deposition and geometric distortions at corner segments.
  • To enhance dimensional consistency and surface quality in additive manufacturing of curved components.

Main Methods:

  • A corner-oriented path-optimization strategy based on geometric code parsing was developed.
  • The method operates directly on the toolpath, without altering CAD models or slicing workflows.
  • This approach specifically targets and suppresses issues at corner segments during deposition.

Main Results:

  • The proposed strategy effectively suppresses corner overbuild and morphological distortion.
  • Significant improvements in dimensional consistency and surface quality were achieved.
  • The method demonstrated enhanced geometric fidelity for curved-surface additive manufacturing.

Conclusions:

  • The developed path-optimization strategy overcomes limitations in curved-surface LC-DED.
  • This approach offers a scalable and broadly applicable solution for high-precision manufacturing.
  • It paves the way for reliable, industrial-scale additive manufacturing of complex metallic components with curved surfaces.