Warhead structures and features are fabricated using direct manufacturing
technologies, a method for fabricating bulk warhead structures by
sequential and additive deposition of melted feedstock layers. Suitable
energy sources for melting the feedstock can be various high energy
density technologies including laser, electron beam, plasma arc
deposition, and the like. The high energy density in combination with
high cooling rates results in structures with homogeneous
microstructures. The feedstock can be in the form of wire or powder and
is applied to a substrate by introduction to a molten pool on the
substrate, accumulating to additively combine with the substrate. The
approach provides for warhead structures with singular and combined
unique features to include: integral constructions, tailored
fragmentation patterns, use of dissimilar materials for special effects,
and variable material property constructions for enhanced performance.