Addressing the next generation of EHLA manufacturing challenges
In plain English
AI plain-English summaryA new laser-based metal deposition process called Extreme High-speed Laser Application (EHLA) is moving from the lab into UK factories, and this renewal grant aims to solve the manufacturing challenges that come with scaling it up. EHLA works by spraying metal powder into a high-speed laser beam, fusing it onto a surface much faster and with less waste than conventional techniques. The original Fellowship proved the process works for coating and repairing rotationally symmetric parts—like turbine shafts or hydraulic rods—and companies are now industrialising it. But applying EHLA to complex, freeform shapes—such as custom repair patches or intricate add-on features—remains unreliable. The research also lacks the digital tools and quality assurance methods needed for consistent, certified production. If successful, this work could make EHLA a standard tool for repairing high-value engineering components—saving energy, material, and cost compared to replacing them. It could also enable new additive manufacturing designs that are currently impossible with slower deposition methods. The project will build the UK’s first dedicated EHLA research facility at The Welding Institute, creating a reference hub of expertise for industry. The four research pillars—technology uptake, freeform industrialisation, novel ideas, and digital quality assurance—are all aimed at turning a promising prototype process into a reliable manufacturing workhorse.
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