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 |
Empirical Calibration and Slicer Implementation of Inclination-Aware Boundary Path Offsets for Wire-Fed Directed Energy Deposition |
| Author(s) |
Liam White, Andrzej Nycz, Alex Arbogast, Chris Masuo, Michael Sebok, Alex Walters, William Carter |
| On-Site Speaker (Planned) |
Liam White |
| Abstract Scope |
Wire-fed directed energy deposition can produce boundary-specific dimensional error when molten beads sag or spread at free edges, especially on overhanging or inclined deposition surfaces. Non-gravity-aligned torch planning expands printable overhangs, but boundary quality remains sensitive to angle-dependent melt-pool deformation, start/stop transients, and path placement. This paper presents an empirical boundary-offset calibration method for multi-bead WAAM. For a fixed material, process recipe, and torch-orientation schedule, calibration coupons are printed across selected overhang and deposition-surface angles with swept absolute offsets applied locally only to exterior and internal boundary paths. Laser scanning and sectioning quantify signed boundary error, edge-height loss, and overcorrection. These measurements define a response surface for selecting a boundary-normal offset as a function of local overhang and deposition-surface angle. The calibrated offset is implemented in a custom WAAM slicer on every layer while preserving interior bead spacing, heat input, and deposition parameters, and is validated on inclined boundary-feature coupons. |
| Proceedings Inclusion? |
Undecided |