Design and Development of a Robust Open-Source Wire Arc Additive Manufacturing Platform

IF 2.8 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters Pub Date : 2026-10-01 Epub Date: 2026-10-05 DOI:10.1016/j.mfglet.2026.07.020

Vishnu Ramasamy, Michael Bastuga, Jacob G. Gregg, John J. Lewandowski

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Abstract

Wire Arc Additive Manufacturing (WAAM) offers a cost-effective method for producing large-scale metallic components, yet its adoption remains constrained by the complexity and high capital cost of existing systems. This work presents a fully open-source, low-cost gantry-style WAAM platform called Arc One, engineered for mechanical rigidity, effective thermal isolation, scalability, and ease of customization. The system integrates commercially available welding hardware with modern open-source control architecture, enabling reliable large-scale deposition for research and training purposes. A 14 lb. thick-walled 316LSi stainless steel structure was fabricated to validate performance against comparable industrial WAAM builds. Real-time process data and subsequent material characterization confirmed stable deposition behavior with microstructural and hardness properties comparable to industrial systems for simple thick-walled geometries. All design files, firmware, and deposition data were released under open access to promote broader engagement in WAAM technology development.

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健壮的开源电弧增材制造平台的设计与开发

电弧增材制造（WAAM）为生产大型金属部件提供了一种经济有效的方法，但其采用仍然受到现有系统的复杂性和高资本成本的限制。这项工作提出了一个完全开源，低成本的龙门式WAAM平台，称为Arc One，具有机械刚性，有效的热隔离，可扩展性和易于定制的特点。该系统将商用焊接硬件与现代开源控制架构集成在一起，为研究和培训目的提供可靠的大规模沉积。制作了一个14磅厚壁316LSi不锈钢结构，以验证与同类工业WAAM结构的性能。实时工艺数据和随后的材料表征证实了稳定的沉积行为，其显微结构和硬度性能可与简单厚壁几何形状的工业系统相媲美。所有的设计文件、固件和沉积数据都以开放的方式发布，以促进WAAM技术开发的广泛参与。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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