Extending wire-arc directed energy deposition using non-gravity aligned (NGA) torch methods

J. Logan McNeil; Joshua J. Penney; Matthew Lamsey; William R. Hamel; Michael Sebok; Saket Thapliyal; Luke Meyer; Mark Noakes; Andrzej Nycz

doi:10.1016/j.jmapro.2025.07.062

Extending wire-arc directed energy deposition using non-gravity aligned (NGA) torch methods

J. Logan McNeil, Joshua J. Penney, Matthew Lamsey, William R. Hamel, Michael Sebok, Saket Thapliyal, Luke Meyer, Mark Noakes, Andrzej Nycz

Research output: Contribution to journal › Article › peer-review

Abstract

For standard Additive Manufacturing (AM) processes, traditional path planning typically relies on a 2.5-dimensional approach. In wire-arc directed energy deposition (DED), commonly referred to as wire-arc additive manufacturing (WAAM), this 2.5D approach inherently limits final near net shape due to the stair-step effect and restricts the maximum overhang angle achievable without part degradation. To achieve better near net shape and part quality, a 3D planning approach that modulates the tool tip position and angle without process changes is demonstrated in components containing up to 105° of unsupported overhang. The experimental methods are validated with half and fully enclosed cylinder sections containing 90° of overhang. The non-gravity aligned methods are then applied to a commercial WAAM system for a composite tool mold demonstrator part. The methods developed in this paper enable expansion of WAAM system capabilities to parts containing large overhangs without compromising the net shape or material structure of the resulting parts and without the need for a part positioner.

Original language	English
Pages (from-to)	139-153
Number of pages	15
Journal	Journal of Manufacturing Processes
Volume	152
DOIs	https://doi.org/10.1016/j.jmapro.2025.07.062
State	Published - Oct 30 2025

Funding

Research sponsored by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office, under contract DE-AC05-00OR22725 with UT-Battelle, LLC. Thank you to Lincoln Electric for their support on the composite tool mold by providing equipment and materials for this project at the Manufacturing Demonstration Facility. Research sponsored by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office, under contract DE-AC05-00OR22725 with UT-Battelle, LLC. Thank you to Lincoln Electric for their support on the composite tool mold by providing equipment and materials for this project at the Manufacturing Demonstration Facility. The authors would like to acknowledge the Manufacturing and Materials Joining Innovation Center (Ma2JIC), funded through an award (02-UTK-012019) from the National Science Foundation Industry University Cooperative Research Center program (IUCRC), for financial support as well as Miller Electric and Oak Ridge National Laboratory for their expertise and in-kind support of this project at the University of Tennessee campus. Additionally, the authors would like to thank Ethan Vals (UTK) for his support in data processing, running experiments in the lab, and providing general lab support for this project. His time in the lab running builds and doing analysis is greatly appreciated. The authors would also like to thank Dustin Wagner for his support in integrating and helping with welding power supply settings with the University of Tennessee system, as well as his support of this project through MA2JIC. The authors would like to acknowledge the Manufacturing and Materials Joining Innovation Center (Ma2JIC) , funded through an award ( 02-UTK-012019 ) from the National Science Foundation Industry University Cooperative Research Center program (IUCRC) , for financial support as well as Miller Electric and Oak Ridge National Laboratory for their expertise and in-kind support of this project at the University of Tennessee campus . This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( http://energy.gov/downloads/doe-public-access-plan ).

Keywords

Additive manufacturing
Path planning
Process control
Wire arc additive manufacturing

Access to Document

10.1016/j.jmapro.2025.07.062

Cite this

@article{2d66736fd8d84d7ca25f3de5b7d1a91e,

title = "Extending wire-arc directed energy deposition using non-gravity aligned (NGA) torch methods",

abstract = "For standard Additive Manufacturing (AM) processes, traditional path planning typically relies on a 2.5-dimensional approach. In wire-arc directed energy deposition (DED), commonly referred to as wire-arc additive manufacturing (WAAM), this 2.5D approach inherently limits final near net shape due to the stair-step effect and restricts the maximum overhang angle achievable without part degradation. To achieve better near net shape and part quality, a 3D planning approach that modulates the tool tip position and angle without process changes is demonstrated in components containing up to 105° of unsupported overhang. The experimental methods are validated with half and fully enclosed cylinder sections containing 90° of overhang. The non-gravity aligned methods are then applied to a commercial WAAM system for a composite tool mold demonstrator part. The methods developed in this paper enable expansion of WAAM system capabilities to parts containing large overhangs without compromising the net shape or material structure of the resulting parts and without the need for a part positioner.",

keywords = "Additive manufacturing, Path planning, Process control, Wire arc additive manufacturing",

author = "McNeil, \{J. Logan\} and Penney, \{Joshua J.\} and Matthew Lamsey and Hamel, \{William R.\} and Michael Sebok and Saket Thapliyal and Luke Meyer and Mark Noakes and Andrzej Nycz",

note = "Publisher Copyright: {\textcopyright} 2025",

year = "2025",

month = oct,

day = "30",

doi = "10.1016/j.jmapro.2025.07.062",

language = "English",

volume = "152",

pages = "139--153",

journal = "Journal of Manufacturing Processes",

issn = "1526-6125",

publisher = "Elsevier",

}

TY - JOUR

T1 - Extending wire-arc directed energy deposition using non-gravity aligned (NGA) torch methods

AU - McNeil, J. Logan

AU - Penney, Joshua J.

AU - Lamsey, Matthew

AU - Hamel, William R.

AU - Sebok, Michael

AU - Thapliyal, Saket

AU - Meyer, Luke

AU - Noakes, Mark

AU - Nycz, Andrzej

PY - 2025/10/30

Y1 - 2025/10/30

N2 - For standard Additive Manufacturing (AM) processes, traditional path planning typically relies on a 2.5-dimensional approach. In wire-arc directed energy deposition (DED), commonly referred to as wire-arc additive manufacturing (WAAM), this 2.5D approach inherently limits final near net shape due to the stair-step effect and restricts the maximum overhang angle achievable without part degradation. To achieve better near net shape and part quality, a 3D planning approach that modulates the tool tip position and angle without process changes is demonstrated in components containing up to 105° of unsupported overhang. The experimental methods are validated with half and fully enclosed cylinder sections containing 90° of overhang. The non-gravity aligned methods are then applied to a commercial WAAM system for a composite tool mold demonstrator part. The methods developed in this paper enable expansion of WAAM system capabilities to parts containing large overhangs without compromising the net shape or material structure of the resulting parts and without the need for a part positioner.

AB - For standard Additive Manufacturing (AM) processes, traditional path planning typically relies on a 2.5-dimensional approach. In wire-arc directed energy deposition (DED), commonly referred to as wire-arc additive manufacturing (WAAM), this 2.5D approach inherently limits final near net shape due to the stair-step effect and restricts the maximum overhang angle achievable without part degradation. To achieve better near net shape and part quality, a 3D planning approach that modulates the tool tip position and angle without process changes is demonstrated in components containing up to 105° of unsupported overhang. The experimental methods are validated with half and fully enclosed cylinder sections containing 90° of overhang. The non-gravity aligned methods are then applied to a commercial WAAM system for a composite tool mold demonstrator part. The methods developed in this paper enable expansion of WAAM system capabilities to parts containing large overhangs without compromising the net shape or material structure of the resulting parts and without the need for a part positioner.

KW - Additive manufacturing

KW - Path planning

KW - Process control

KW - Wire arc additive manufacturing

UR - https://www.scopus.com/pages/publications/105012587958

U2 - 10.1016/j.jmapro.2025.07.062

DO - 10.1016/j.jmapro.2025.07.062

M3 - Article

AN - SCOPUS:105012587958

SN - 1526-6125

VL - 152

SP - 139

EP - 153

JO - Journal of Manufacturing Processes

JF - Journal of Manufacturing Processes

ER -

Extending wire-arc directed energy deposition using non-gravity aligned (NGA) torch methods

Abstract

Funding

Keywords

Access to Document

Other files and links

Fingerprint

Cite this