Kaji, FarzanehJinoop, Arackal NarayananZimny, MarkFrikel, GermanTam, KyleToyserkani, Ehsan2022-02-022022-02-022022-01https://doi.org/10.1016/j.addlet.2022.100035http://hdl.handle.net/10012/18041In the present work, a novel Laser Directed Energy Deposition (LDED) process planning methodology is proposed to build a dome structure with variable overhang angles. Overhang structures with different overhang angles were built where the maximum angle of 35° can be used to build overhang structures without the process and structure compromise. The thin-wall hemispherical dome built using the developed methodology shows the maximum deviation of 2% with respect to the diameter of the original CAD model data. The study paves a way for building high-value, lightweight thin-walled structures with complex cylindrical-based shape (e.g., storage tanks, nozzles, combustion chambers) for engineering applications.enAttribution-NonCommercial-NoDerivatives 4.0 Internationalhttp://creativecommons.org/licenses/by-nc-nd/4.0/laser directed energy depositionprocess planningtool path generationoverhang geometryadditive manufacturingArticle