If you’re passionate about pushing the boundaries of additive manufacturing, this is for you. In a must-watch IMTS+ interview, Melanie Lang, co-founder and CEO of FormAlloy, dives into the state and future of direct energy deposition (DED) for additive manufacturing. From the company’s new wire module to a game-changing, AI-free PAT system that generates tool paths without CAD models (yes, really!), we explore how DED is unlocking new frontiers in repair and remanufacturing for aerospace, defense, supply chain challenges, and beyond.  Understanding DED: Speed, Versatility, and Impact  DED is a laser-based metal AM process that deposits material layer by layer and can use both powder and wire. Lang notes that wire enables deposition rates two to three times faster than powder, making it ideal for simple geometries like tubes or parts with long lead times, such as forgings. Smarter Repairs With AI-Free Toolpath Generationing  FormAlloy’s latest innovation includes a wire module and a new Path technology that allows users to scan parts and auto-generate tool paths from point clouds — no CAD model or AI required. This drastically simplifies the repair process for components with worn or warped areas. Material Mastery and Functional Grading  DED also shines in material versatility. Lang shares that FormAlloy works with steel, stainless, tool steel, nickel superalloys, copper, and refractory alloys. It even enables functionally graded materials (FGMs), where materials can change within a layer or across a part. That means tailored thermal, structural, or electrical performance — printed directly into the part. Repeatability, Control, and Future Possibilities  Consistency is key, and Lang emphasizes FormAlloy’s focus on closed-loop control to ensure repeatable material properties. Maintaining a stable melt pool is central to performance, especially in aerospace and defense where reliability is non-negotiable. Watch the Full Interview As defense contractors face year-long delays for aluminum forgings, DED offers a viable, responsive alternative. With dual-head systems combining powder and wire, plus robotic automation on the horizon, DED is poised to transform how we think about manufacturing, repair, and material design. Additive fans, you’ll want to see this! Whether you're obsessed with AM tech, looking for smarter repair solutions, or just love geeking out over innovation, this interview delivers. Watch “From Tooling to Tubes: The Evolving Promise of DED With Melanie Lang” now on IMTS+ at IMTS.com/TLC-DED. 
The “Tom and Lonnie Chat” crew welcomes back Melanie Lang, co-founder of FormAlloy, for an insightful discussion on the state and future of direct energy deposition additive manufacturing, FormAlloy’s new wire module, their AI-free PATH system that enables automated toolpath generation without CAD models – ideal for repair, remanufacturing, and much more.