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Design and development of open-source, multi-purpose wire arc additive manufacturing machine

2025-05-28Artigo científico Acesso aberto
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dc.contributor.authorArthur, Nithin Joseph Reddy Sagili
dc.contributor.authorLiu, Lei
dc.contributor.authorOliveira, João Pedro
dc.contributor.institutionCENIMAT-i3N - Centro de Investigação de Materiais (Lab. Associado I3N)
dc.contributor.institutionDCM - Departamento de Ciência dos Materiais
dc.contributor.pblSpringer Science Business Media
dc.date.accessioned2025-07-30T21:20:55Z
dc.date.available2025-07-30T21:20:55Z
dc.date.issued2025-05-28
dc.descriptionFunding Information: Open access funding provided by FCT|FCCN (b-on). Nithin Joseph Reddy Sagili Arthur received funding from Fundação para a Ciência e a Tecnologia (FCT) for its financial support via the PhD grant 2022.10356.BD. Lei Liu received the financial support from the China Scholarship Council Grant No. 202208420052. The authors also received funding by national funds from FCT—Fundação para a Ciência e a Tecnologia, I.P., in the scope of the project’s LA/P/0037/2020, UIDP/50025/2020, and UIDB/50025/2020 of the Associate Laboratory Institute of Nanostructures, Nanomodelling and Nanofabrication – i3 N. Publisher Copyright: © The Author(s) 2025.
dc.description.abstractWire arc additive manufacturing (WAAM) is a promising technology offering capabilities of high deposition rate and low processing and equipment setup cost and the possibility to create components with moderate geometrical complexity. However, wide scale industrialization of this technology is constrained by its complex thermal signature which demands an interdisciplinary approach of integrating auxiliary technologies aiming at controlling and monitoring the process often requiring costly upgrades of ancillary systems. These challenges can be addressed by developing flexible and adaptable WAAM systems that incorporate open-source solutions for developing innovative and customized auxiliary add-ons mitigating proprietary barriers and scale-up expenditures. In this work, we present the design and construction of a scalable WAAM machine featuring three-axis rectilinear motion system with a working envelope suited for small- to medium-sized components. The system integrates a customized weld torch and multiple wire feeder utilizing widely available materials to ensure functionality and cost-effectiveness. An open-source 32-bit control board is employed to achieve coordinated operation of multiple systems. A detailed assessment and selection criteria of various motion control hardware is provided. Additionally, pioneering summary of control boards with significant potential for expansion into metal additive manufacturing is also presented. To validate the machine functionality, multi-layer deposition along X–Z and multi-bead deposition along X–Y axes were conducted. These results demonstrate the seamless synchronization of the motion control, welder, and wire feeder systems, achieving defect-free depositions. Conductive and radiative electromagnetic interference mitigation measures are detailed, providing a practical guidance to simplify the development of customizable WAAM machines.en
dc.description.versionpublishersversion
dc.description.versionpublished
dc.format.extent20
dc.format.extent3079395
dc.identifier.doi10.1007/s00170-025-15754-x
dc.identifier.issn0268-3768
dc.identifier.otherPURE: 123412880
dc.identifier.otherPURE UUID: 4fa942a1-e1ba-4d8c-be13-cce11da04dae
dc.identifier.otherScopus: 105006918767
dc.identifier.otherWOS: 001498138400001
dc.identifier.otherORCID: /0000-0001-6906-1870/work/188937290
dc.identifier.urihttp://hdl.handle.net/10362/185776
dc.identifier.urlhttps://www.scopus.com/pages/publications/105006918767
dc.identifier.urlhttps://www.webofscience.com/wos/woscc/full-record/WOS:001498138400001
dc.language.isoeng
dc.peerreviewedyes
dc.relationinfo:eu-repo/grantAgreement/FCT/OE/2022.10356.BD/PT
dc.relationinfo:eu-repo/grantAgreement/FCT/6817 - DCRRNI ID/LA%2FP%2F0037%2F2020/PT
dc.relationInstitute of Nanostructures, Nanomodelling and Nanofabrication
dc.relationInstitute of Nanostructures, Nanomodelling and Nanofabrication
dc.relationinfo:eu-repo/grantAgreement/FCT/Concurso de avaliação no âmbito do Programa Plurianual de Financiamento de Unidades de I&D (2017%2F2018) - Financiamento Base/UIDB%2F50025%2F2020/PT
dc.subjectElectromagnetic shielding
dc.subjectMachine design
dc.subjectMotion control system
dc.subjectTwin wire thin wall depositions
dc.subjectWelder and wire feeder system
dc.subjectControl and Systems Engineering
dc.subjectSoftware
dc.subjectMechanical Engineering
dc.subjectComputer Science Applications
dc.subjectIndustrial and Manufacturing Engineering
dc.titleDesign and development of open-source, multi-purpose wire arc additive manufacturing machineen
dc.typejournal article
degois.publication.firstPage4337
degois.publication.lastPage4356
degois.publication.titleInternational Journal Of Advanced Manufacturing Technology
degois.publication.volume138
dspace.entity.typePublication
oaire.awardNumber2022.10356.BD
oaire.awardNumberLA/P/0037/2020
oaire.awardNumberUIDP/50025/2020
oaire.awardNumberUIDB/50025/2020
oaire.awardTitleInstitute of Nanostructures, Nanomodelling and Nanofabrication
oaire.awardTitleInstitute of Nanostructures, Nanomodelling and Nanofabrication
oaire.awardURIinfo:eu-repo/grantAgreement/FCT/OE/2022.10356.BD/PT
oaire.awardURIinfo:eu-repo/grantAgreement/FCT/6817 - DCRRNI ID/LA%2FP%2F0037%2F2020/PT
oaire.awardURIinfo:eu-repo/grantAgreement/FCT/6817 - DCRRNI ID/UIDP%2F50025%2F2020/PT
oaire.awardURIinfo:eu-repo/grantAgreement/FCT/Concurso de avaliação no âmbito do Programa Plurianual de Financiamento de Unidades de I&D (2017%2F2018) - Financiamento Base/UIDB%2F50025%2F2020/PT
oaire.fundingStreamOE
oaire.fundingStream6817 - DCRRNI ID
oaire.fundingStream6817 - DCRRNI ID
oaire.fundingStreamConcurso de avaliação no âmbito do Programa Plurianual de Financiamento de Unidades de I&D (2017/2018) - Financiamento Base
project.funder.identifierhttp://doi.org/10.13039/501100001871
project.funder.identifierhttp://doi.org/10.13039/501100001871
project.funder.identifierhttp://doi.org/10.13039/501100001871
project.funder.identifierhttp://doi.org/10.13039/501100001871
project.funder.nameFundação para a Ciência e a Tecnologia
project.funder.nameFundação para a Ciência e a Tecnologia
project.funder.nameFundação para a Ciência e a Tecnologia
project.funder.nameFundação para a Ciência e a Tecnologia
rcaap.rightsopenAccess
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