Process planning for laser wire-feed metal additive manufacturing system

  • Yaoyu Ding
  • Meysam Akbari
  • Radovan Kovacevic


Laser wire-feed metal additive manufacturing (LWMAM) is a promising additive manufacturing technology that is well suited to build from various materials near net shape mid- to large-size complex components with a high deposition rate and high material usage. It could find applications in diverse industrial sectors such as aerospace, automotive, oil and gas, and rapid tooling. To further gain the acceptance of this technology, the development of process planning software is identified as one of the main challenges. LWMAM has several specific features that complicate the process planning compared to other similar additive manufacturing processes. LWMAM is still in its infancy. In this study, key features involved in the LWMAM process were first identified by building a prismatic block. The corresponding strategies were proposed and tested. Then, a MATLAB-based process planning software was developed that consisted of modules for volume slicing, contour filling, track trimming/elongating, stair-step effect compensation, and post-processing. Free-form contours and a propeller were successfully built by using the developed software. The as-built shapes were measured and compared to the CAD models.


Laser Wire Metal additive manufacturing Process planning Stair-step Propeller 


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The authors would like to thank Mr. Andrew Socha at the Research Center for Advanced Manufacturing at SMU for his assistance in this research. The financial support of National Science Foundation of USA under the Grant IIP-1539853 is acknowledged.


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© Springer-Verlag London Ltd. 2017

Authors and Affiliations

  1. 1.Department of Mechanical Engineering, Research Center for Advanced ManufacturingSouthern Methodist UniversityDallasUSA

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