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<p>This paper explores a novel path planning and online control method designed to address the challenges of constructing complex geometries, especially those featuring hollow overhangs and significant inclinations. The inherent constraints of layer-by-layer manufacturing often lead to collapses, deformations, and deviations in shape due to insufficient support for molten material during cooling and solidification. Our approach employs a laser scanner to measure the geometry of deposited layers after the completion of specific intervals, comparing these measurements with a preset CAD model to identify deviations. A sophisticated control algorithm then generates a compensation surface to correct these deviations, optimizing the welding path for subsequent layers. This method not only enhances the print quality and success rate of complex parts but also allows for the storage of manufacturing data from the initial piece, facilitating fully automated subsequent prints without the need for manual compensation adjustments.</p>

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A path planning and online compensation method for wire arc additive manufacturing of thin-walled curved hollow structure

  • 期刊论文

  • 发表日期：

    2025年8月9日

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  • Qiang Cui,
  • Zemin Shao

摘要

This paper explores a novel path planning and online control method designed to address the challenges of constructing complex geometries, especially those featuring hollow overhangs and significant inclinations. The inherent constraints of layer-by-layer manufacturing often lead to collapses, deformations, and deviations in shape due to insufficient support for molten material during cooling and solidification. Our approach employs a laser scanner to measure the geometry of deposited layers after the completion of specific intervals, comparing these measurements with a preset CAD model to identify deviations. A sophisticated control algorithm then generates a compensation surface to correct these deviations, optimizing the welding path for subsequent layers. This method not only enhances the print quality and success rate of complex parts but also allows for the storage of manufacturing data from the initial piece, facilitating fully automated subsequent prints without the need for manual compensation adjustments.