Design and integration of WAAM technology and in situ monitoring system in a gantry machine

Wire arc additive manufacturing, WAAM, is a popular wire-feed additive manufacturing technology that creates components through the deposition of material layer-by-layer. WAAM has become a promising alternative to conventional machining due to its high deposition rate, environmental friendliness and cost-competitiveness. In this research work, an adaptation of a gantry machine with in-situ monitoring and a control system has been carried out, in order to expose the ability of the WAAM technology to fabricate complex-shaped parts. The retrofitting of the machine has been done in several layers called respectively hardware, control and software layers. For the validation of the implemented system, a stainless steel 316L demonstrator has been manufactured, and the required stages have been employed, including part design (CAD), process parameters selection, tool-path definition (CAM) and part manufacturing. This study has shown the feasibility of the adapted machine for additive manufacturing as a controlled process.