Slicer and process improvements for open-source GMAW-based metal 3-D printing

Nilsiam, Yuenyong; Sanders, Paul G.; Pearce, Joshua M.

doi:10.1016/j.addma.2017.10.007

Cited by 22 publications

(12 citation statements)

References 27 publications

(16 reference statements)

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“…Since most of the software for metal deposition are limited and without public access, Yunyong et al [114] took advantage of the free open source CuraEngine to introduce new settings to generate G-code to print metallic parts. These settings permit the torch to toggle on and off, path optimization to avoid crossovers in the same layers, the number of start/stops are minimized, and an option to pause the torch was also added for subtract cooling between layers.…”

Section: Deposition Strategymentioning

confidence: 99%

Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM)

et al. 2019

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Additive manufacturing has revolutionized the manufacturing paradigm in recent years due to the possibility of creating complex shaped three-dimensional parts which can be difficult or impossible to obtain by conventional manufacturing processes. Among the different additive manufacturing techniques, wire and arc additive manufacturing (WAAM) is suitable to produce large metallic parts owing to the high deposition rates achieved, which are significantly larger than powder-bed techniques, for example. The interest in WAAM is steadily increasing, and consequently, significant research efforts are underway. This review paper aims to provide an overview of the most significant achievements in WAAM, highlighting process developments and variants to control the microstructure, mechanical properties, and defect generation in the as-built parts; the most relevant engineering materials used; the main deposition strategies adopted to minimize residual stresses and the effect of post-processing heat treatments to improve the mechanical properties of the parts. An important aspect that still hinders this technology is certification and nondestructive testing of the parts, and this is discussed. Finally, a general perspective of future advancements is presented.

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Section: Deposition Strategymentioning

confidence: 99%

Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM)

et al. 2019

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“…The desired T REF for stable deposit was obtained experimentally. Similar to the approach Nilsiam et al [22] have taken, open-source Cura 3D slicer [26] is used to create the layer path from the CAD model and the output G-code for motion control. A custom script is used on the output G-code to add correct subroutines, inputs and control outputs {T c , H c , V c } for temperature control, cooling and deposition.…”

Section: The Waam Systemmentioning

confidence: 99%

“…One of the benefits of using a three-axis positioning system is the ability to use path-generation software dedicated to FDM printers, with some modifications required to make them suitable for WAAM. Nilsiam et al [22] introduced a WAAM slicer for welding path generation by modifying an open-source Cura slicer. Their solution included a certain degree of WAAM-related path optimisation; however, they encountered the problem of heat accumulation during case studies, since their system also did not include interpass temperature control or cooling.…”

Section: Introductionmentioning

confidence: 99%

WAAM system with interpass temperature control and forced cooling for near-net-shape printing of small metal components

Kozamernik

Bračun

Klobčar

2020

Int J Adv Manuf Technol

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In an attempt to find a solution similar to the FDM 3D printers which would allow cost-effective and reliable additive manufacturing of metal components, this paper proposes a three-axis WAAM system capable of reliably printing small, near-net-shape metal objects. The system consists of gas metal arc (GMA) process equipment, a three-axis CNC positioning system, the interpass temperature control and forced cooling of the base plate and the deposit. The main challenge addressed is the minimisation of shape distortions caused by excessive heat accumulation when printing small objects. The interpass temperature control uses an IR pyrometer to remotely measure the last deposited layer and a control system to keep the interpass temperature below the predefined value by stopping the deposition after each layer in order to allow the deposit to cool. This results in a stable and more repeatable shape of the deposit, even when the heat transfer conditions are changing during the build-up process. The combination of adaptive interlayer dwell time and forced cooling significantly improves system productivity. Open-source NC control and path generation software is used, which enables fast and easy creation of the control code. Different control methods are evaluated through the printing of simple walls, and the printing accuracy is evaluated by printing small shell objects. As the results show, the interpass temperature control allows small objects to be printed at near-net shape with a deviation of 2%, which means that successful printing of 3D shapes can be achieved without trial and error approach.

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“…MOSTMetalCura [34] is a customized version of CuraEngine for metal 3-D printing. It slices a 3-D model into 2-D layers and generates toolpaths for each layer.…”

Section: Methodsmentioning

confidence: 99%

Applications of Open Source GMAW-Based Metal 3-D Printing

Nilsiam

Sanders

Pearce

2018

JMMP

Self Cite

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The metal 3-D printing market is currently dominated by high-end applications, which make it inaccessible for small and medium enterprises, fab labs, and individual makers who are interested in the ability to prototype and additively manufacture final products in metal. Recent progress led to low-cost open-source metal 3-D printers using a gas metal arc welding (GMAW)-based print head. This reduced the cost of metal 3-D printers into the range of desktop prosumer polymer 3-D printers. Consequent research established good material properties of metal 3-D printed parts with readily-available weld filler wire, reusable substrates, thermal and stress properties, toolpath planning, bead-width control, mechanical properties, and support for overhangs. These previous works showed that GMAW-based metal 3-D printing has a good adhesion between layers and is not porous inside the printed parts, but they did not proceed far enough to demonstrate applications. In this study, the utility of the GMAW approach to 3-D printing is investigated using a low-cost open-source metal 3-D printer and a converted Computer Numerical Control router machine to make useful parts over a range of applications including: fixing an existing part by adding a 3-D metal feature, creating a product using the substrate as part of the component, 3-D printing in high resolution of useful objects, near net objects, and making an integrated product using a combination of steel and polymer 3-D printing. The results show that GMAW-based 3-D printing is capable of distributed manufacturing of useful products for a wide variety of applications for sustainable development.

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Slicer and process improvements for open-source GMAW-based metal 3-D printing

Cited by 22 publications

References 27 publications

Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM)

Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM)

WAAM system with interpass temperature control and forced cooling for near-net-shape printing of small metal components

Applications of Open Source GMAW-Based Metal 3-D Printing

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