Embedding Electronics Inside Metal with Laser Metal Deposition

Laser metal deposition (LMD) is an additive manufacturing technology that allows layer by layer fabrication on existing metal parts. Integration of sensors inside the recipient sheet metals with LMD may result in smart components with enhanced functionalities, which would lead to machine tools with inherent sensing capabilities. However, special measures are necessary to prevent typical sensors from being damaged by excessive heat produced because of LMD. This work present results of an experiment performed to embed electronic device, also known as microdevice, such as photodiodes, inside sheet metal with LMD. Results show the level of degradation of material and electronic performance after being embedded inside metal. The presented method of integrating electronics inside metal shows potential for developing multifunctional components while providing structural integrity for high performance industry such as automotive and aerospace. Future work will focus on developing insulation method and optimizing thermal management of sensors being welded inside metal.