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About this Abstract
Meeting 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Symposium 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Presentation Title Experimental Evaluation of Unsupported Overhang Limits in Steel Parts Fabricated by Wire-Based Directed Energy Deposition
Author(s) Youssef K Hamidi, Josiah White, Caleb Cannon, Kazi Md Masum Billah
On-Site Speaker (Planned) Josiah White
Abstract Scope Wire-based directed energy deposition (DED) enables the fabrication of large-scale metal components with reduced material waste and increased design flexibility. However, unsupported overhang fabrication remains a significant challenge due to thermal instability, bead sagging, and insufficient interlayer support during deposition. This study experimentally investigates the support-free overhang capability of steel structures fabricated using a Meltio M450 system. Steel wall specimens with varying overhang angles were printed under constant processing conditions to determine the maximum printable unsupported geometry. The effects of overhang angle on dimensional accuracy, bead morphology, surface quality, and structural stability were evaluated. Failure mechanisms including collapse, excessive deformation, and discontinuous deposition were analyzed through visual inspection and geometric measurements. The results provide practical design guidelines for unsupported overhang fabrication in wire-based DED and contribute to improving process reliability for complex metal additive manufacturing applications.
Proceedings Inclusion? Undecided

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