Design and development of open-source, multi-purpose wire arc additive manufacturing machine

Abstract Wire arc additive manufacturing (WAAM) is a promising technology offering capabilities of high deposition rate and low processing and equipment setup cost and the possibility to create components with moderate geometrical complexity. However, wide scale industrialization of this technology is constrained by its complex thermal signature which demands an interdisciplinary approach of integrating auxiliary technologies aiming at controlling and monitoring the process often requiring costly upgrades of ancillary systems. These challenges can be addressed by developing flexible and adaptable WAAM systems that incorporate open-source solutions for developing innovative and customized auxiliary add-ons mitigating proprietary barriers and scale-up expenditures. In this work, we present the design and construction of a scalable WAAM machine featuring three-axis rectilinear motion system with a working envelope suited for small- to medium-sized components. The system integrates a customized weld torch and multiple wire feeder utilizing widely available materials to ensure functionality and cost-effectiveness. An open-source 32-bit control board is employed to achieve coordinated operation of multiple systems. A detailed assessment and selection criteria of various motion control hardware is provided. Additionally, pioneering summary of control boards with significant potential for expansion into metal additive manufacturing is also presented. To validate the machine functionality, multi-layer deposition along X–Z and multi-bead deposition along X–Y axes were conducted. These results demonstrate the seamless synchronization of the motion control, welder, and wire feeder systems, achieving defect-free depositions. Conductive and radiative electromagnetic interference mitigation measures are detailed, providing a practical guidance to simplify the development of customizable WAAM machines.