Laser metal deposition (LMD) is an additive-manufacturing process that sees metal powder fed into a laser beam scanning across a surface.

Milan Brandt of RMIT University in Melbourne (Australia), who is leading research into this technology, said: “LMD is basically a very high-tech welding process that allows us to make or rebuild metal parts layer by layer.

"The bond created by LMD is exceptionally strong, making the process a viable method for both manufacturing spare parts and repairing existing parts. The repaired part is just as strong as — or in some cases even stronger than — the original.”

Professor Brandt said that the concept is proven and that prospects for its successful development are positive, adding that his research team sees the technology being applied to existing military aircraft platforms as well as newer systems, such as the F-35 fleet.

“The estimated total cost of replacing damaged aircraft parts for the Australian Air Force is currently more than $230 million a year, so the move to additively manufactured components produced locally would have a significant impact.

“The team is evaluating expectations that LMD technology will effect real cost savings in the areas of maintenance and spare parts purchasing, scrap metal management, and warehousing and shipping costs.”

Neil Matthews, senior manager of advanced technology and engineering solutions at RUAG Australia (www.ruag.com) — a precision manufacturing, MRO, metal treatment and finishing and engineering company — said: “Strategically speaking, a shift to LMD technology means less down-time for repairs and a dramatic increase in the availability and readiness of aircraft.

“Implementing LMD technology means that parts could be built or repaired on site, so instead of waiting for spare parts to arrive from a warehouse, an effective solution will now be available locally.

“Moreover, this technology could be applied in any industry where metal degradation or the remanufacture of parts is an issue.

“The current project focuses on military aircraft, but it is potentially transferable to the civil aircraft, marine, rail, mining, and oil and gas industries.”