Directed Plasma Fabrication (DPF) is a rapid tooling process that is based on controlled deposition of molten powder particles according to computer-controlled patterns. It makes fully dense, near net shape metal components without molds or dies, and without forming, pressing or forging systems.
Experimental works were carried out using conventional low current Plasma Transferred Arc Welding system, and metallic powder was stellite #21. Cylindrical shapes are successfully deposited as dimensions with 2.5-4.2 mm wall thickness.
As compared to thermal conductivity, there is considerable effect of some physical factors like arc force on the penetration depth of the molten pool, during DPF process. And, if the arc length is appropriately controlled, cross sectional area of molten pool and its penetration depth can be roughly approximated to the heat source assumed to be moving point type.