The benefits of LENS are centered on driving down the lifecycle cost of developing, manufacturing and servicing metal dependent end-products by providing lower production costs, improved functionality and faster time-to-market. Key highlights of the process include:

• Direct input from CAD data reduces setup and tooling costs, and allows for quick design changes
• Single step process reduces operational time and operational costs
• Additive approach reduces material waste and costs
• Additive approach facilitates cost-saving Hybrid Manufacturing alternatives
• Superior mechanical properties lead to longer part life and improved performance
• Novel shapes and material compositions allow for increased design flexibility
• Small Heat-Affected Zone uniquely enables repair of sensitive components

Component Repair
LENS has demonstrated significant Returns on Investment (ROI) for users repairing high-value components, such as those found in the Gas Turbine Engines that power airplanes and military vehicles.

LENS offers both cost and functional advantages for Repair applications. First, LENS can quickly add a very precise amount of material to worn or damaged surfaces, minimizing the required post-processing. And, because LENS is a highly targeted approach, it exposes the part to far less heat than conventional methods, avoiding damage to sensitive components. Finally, a LENS repair has exceptional mechanical properties and interface characteristics, often superior to those of the native material. This means that a LENS repair often outlasts the original surface.

Component Fabrication
LENS is also a compelling component manufacturing solution for Aerospace and Defense markets, due to its ability to produce an entire component with superior mechanical properties in less time and at less cost. Performance advantages are also made possible based on the unique capability of LENS to produce internal hollow structures, and functional material gradients where a single component is made up of multiple materials and properties.

In addition to its ability to produce a complete part, LENS can also be used as a complement to traditional methods to create cost-effective hybrid manufacturing routes where, in example, one would use LENS to add the high-resolution features onto a large cast component, or add a wear-resistant surface.

Titanium Satellite Housing
(Courtesy: Lockheed Martin/ICE Prototyping)

Functional Implants & Surgical Tools
LENS is an emerging solution for medical device manufacturing, including the development, prototyping and production of specialty surgical instruments and prosthetic implants, such as hip, knee and spinal devices.

LENS Titanium Hip Implant

• Materials Properties and Performance
• Flexible/Agile Manufacture
• Economic & Rapid Manufacture

LENS Titanium Suspension
Mounting Bracket
(Courtesy: Red Bull Racing)



LENS Titanium Exhaust Valve
(Courtesy: ICE Prototyping)