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

Wire arc additive manufacturing (WAAM) is a wire-feed additive manufacturing technology that generates components by depositing material layer-by-layer. This approach has emerged as a viable alternative to traditional machining, being favored for its high deposition rate, environmental sustainability, and cost-effectiveness. This study aims to assess the capabilities of WAAM in manufacturing complex-shaped parts through the adaptation of a gantry machine equipped with in-situ monitoring and control systems. The retrofitting process involved three distinct layers: hardware, control, and software. To validate the system's functionality, a stainless steel 316L demonstrator was manufactured, incorporating essential stages such as part design using computer-aided design (CAD), process parameters selection, tool-path definition through computer-aided manufacturing (CAM), and actual part fabrication. The findings indicate that the modified machine can effectively facilitate additive manufacturing as a controlled process. This research highlights the feasibility and potential applications of utilizing WAAM technology for manufacturing complex geometries in various sectors.