The direct metal deposition (DMD) process is drawing considerable contempor
ary interest due to its capability to deliver "Art to Part". DMD can reduce
the lead time For a concept to product by eliminating several intermediate
steps. The most attractive feature of the process is that not only can it
produce functional parts but it can also be interfaced with the homogenizat
ion design method, heterogeneous solid model and computer aided design soft
ware to produce "Designed Material" with desired properties generally not o
bserved in nature. Closed loop DMD is a synthesis of multiple technologies
including lasers, sensors, computer numerical controlled work handling stag
e, CAD/CAM software and cladding metallurgy. This paper describes the metho
dology used to produce a designed macro- and microstructure and reviews the
state of the art for closed loop DMD. (C) 2001 Elsevier Science Ltd. All r
ights reserved.