Additive manufacturing of metals is becoming increasingly important in various industrial sectors, including aviation and space, the energy sector and the automotive and toolmaking industries. More so than with other manufacturing processes, the quality of AM components is based on an in-depth understanding of the interactions between the AM process, the resulting material and the component properties.


This lecture will highlight the coaxial nozzle design approach for powder and wire AM of high-grade materials, including light metals, nickel and titanium alloys, bronze, hard metals or high-entropy alloys. Based on the material properties and the desired component specifications, customized processing heads for coaxial feeding of the material to the laser beam at the working position are available, compatible with conventional laser systems and hybrid AM machines. Some nozzles have been optimized for the use in extreme conditions or confined spaces, while others are designed for particularly fine structures or for high-grade materials. In a recent concept, wire and powder filler material have been combined in one head, opening new horizons in 2D and 3D DED manufacturing. Exemplary components for the aerospace industry as well as high productive laser cladding applications for the automotive and oil and gas industry will be discussed.