Reflective materials, such as gold, silver, and copper, cannot be used in infrared laser based additive manufacturing due to the inability of the infrared laser to melt these materials. However, there is an increasing demand for reflective materials in additive manufacturing, leading to the development of a concept to adapt Green Laser technology, which enables the production of reflective metals, to existing Direct Energy Deposition (DED) technology. This hybrid production method aims to enable the production of metals like copper, which have high reflectivity but are currently unsuitable for production with current AM technologies. The concept involves using a combination of infrared and green lasers, switching between the two lasers depending on the material being used.

The use of green lasers in the hybrid production of reflective materials has several benefits compared to traditional infrared lasers. These benefits include more effective and efficient deposition of parts, increasing production speed by up to 10 times, the ability to produce larger parts, and enabling the hybrid production of materials such as copper and aluminium. The hybrid production method also allows for the creation of multi-material parts and functionally graded reflective materials. In addition, green lasers enable modifications and repairs to be made on existing products made of reflective materials. The use of green lasers in the production process also leads to a reduction in lead time compared to conventional manufacturing methods and results in improved part performance with better density, lower porosity, a better surface finish, less spatter, and a more stable melt pool. This leads to improved productivity and the ability to handle more complex parts.

There are several challenges that need to be addressed in order to fully realize the potential of green lasers in the hybrid production of reflective materials. One challenge is the need for a higher level of precision and control over the laser beam in order to produce high quality parts. Another challenge is the potential for high levels of heat generation, which can lead to distortion and other defects in the finished parts. In addition, there are challenges related to the processing of certain reflective materials, such as the difficulty in achieving a homogenous melt pool and the formation of surface defects. These challenges can be addressed through the development of advanced process control strategies and the optimization of process parameters such as laser power, beam profile, and scan speed. There is also a need for continued research and development in order to improve the overall efficiency and effectiveness of the hybrid production process.

Coşkunöz is interested in the concept of using green lasers in the hybrid production of reflective materials, specifically for the production of hybrid waveguides and hybrid cold plates. Hybrid waveguides are an important component in the telecommunications industry, and the ability to produce these parts using reflective materials would open up new possibilities for their design and functionality. Hybrid cold plates, which are used in the cooling of electronic devices, also have the potential to benefit from the use of reflective materials in their production. The ability to produce these parts using green lasers in a hybrid production process would allow for improved performance and increased efficiency in their manufacture. Coşkunöz is committed to exploring the potential of this technology and working towards the development of advanced production methods for these and other products.