About this Abstract |
| Meeting |
2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
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| Symposium
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2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
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| Presentation Title |
Process Optimization for WAAM Deposition of High-angle Unsupported Geometry without Multi-axis Positioning |
| Author(s) |
Michael Sebok, Alex Arbogast, Chris Masuo, William Carter, Andrzej Nycz, Patxi Fernandez-Zelaia |
| On-Site Speaker (Planned) |
Michael Sebok |
| Abstract Scope |
In previous wire arc additive manufacturing (WAAM) research, the typical limit for unsupported overhang geometries is around 25-30°. Recent compensation techniques have pushed the feasible limits considerably higher, but these methods are usually validated on simplistic single bead geometries or require a multi-axis positioner. This work demonstrates that unsupported geometries can be deposited without bead failure at angles exceeding 75° with a well-tuned deposition process. This method incorporates multiple compensation methods including process control, bead adjustment, and torch reorientation. The slicing process and toolpath generation are also modified to maximize overhang stability. The process was validated on a 1” thick, multi-bead geometry approximating a spherical dome with a continuously varying overhang angle. Unlike other methods for high-angle geometries, a multi-axis positioner is not required. Experimentation was performed using 316LSi material, but all compensation methods are process agnostic and can be transferred to other metals. |
| Proceedings Inclusion? |
Undecided |