Abstract
Directed Energy Deposition (DED) (powder-based) is an additive manufacturing process used in industrial applications for repair, cladding, and part fabrication. The process relies on high-precision, multi-axis robots to control the deposition path in three-dimensional space. Final quality of DED generated material is paramount, yet the dynamic nature of robotic systems introduces complexities difficult to monitor and control in real-time.<br>The operation of high-power laser sources and the rapid, dynamic movements of the multi-axis robot generate significant conducted Electromagnetic Interference (EMI). Traditionally, this EMI is treated solely as a compliance issue. This work, however, explores the hypothesis that the real-time EMI spectrum is a valuable, non-intrusive proxy for the dynamic state of the entire LPD system, both the robot's motion and the local welding process.