MatCap: Capacity building within materials for the defense of the future - DEDCap: On-site repair and metal 3D printing for the defense

DEDCap builds and anchors a strong Danish capacity within Direct Energy Deposition (DED). The goal is to make forward-deployed repair and rapid metal production usable for the Armed Forces, enabling worn-out or damaged components to be restored directly in the field.

The challenge: Vulnerable supply lines and long lead times for spare parts

When critical defense components, such as armored parts, drivetrains, or specially designed structural elements, are damaged or worn, replacement often involves months of lead time and dependence on global subcontractors. During forward-deployed missions, the lack of a single spare part can mean that vital equipment is taken out of service.

Conventional repair methods are often inadequate for advanced alloys, and traditional machining cannot recreate complex geometries on site. There is a lack of standardized and validated methods for the rapid deposition of metal and the combination of different materials.

The solution: DED technology for repair and multi-materials

Direct Energy Deposition (DED) is a form of additive manufacturing (3D printing) where a focused energy source (laser or arc) melts metal powder or wire as it is deposited onto the component. This enables both the new manufacturing of components and the direct addition of wear-resistant material onto damaged parts.

Expected results and impact

• Demonstrators: Tangible examples of the repair of armored parts and optimized components for harsh operational environments.
• Follow-up defense applications: Establishment of an industrial consortium serving as the basis for 1–2 major applications under the European Defence Fund (EDF) or Innovation Fund Denmark.

Contact

Would you like to learn more about DED technology or join the professional advisory group? Contact business manager, PhD, and project manager, Ellen Hedegaard.