Metal Additive Manufacturing Conference - MAMC 2026

Parameter selection in wire arc Directed Energy Deposition (wa-DED) is inherently complex due to the large number of interdependent process variables. For weaving strategies in particular, no straightforward empirical rules exist across varying deposition rates. This makes trial-and-error approaches costly and unreliable. This work presents a systematic, geometry-based derivation of key weaving parameters, including weaving half-length and tangential/orthogonal torch velocity components. These are derived from cross-sectional geometry and substrate conditions. The approach ensures that slow-response subsystems, such as wire feed, are not overloaded during trajectory execution. Building on prior modeling and control work for single-seam deposition, where geometric relationships proved especially valuable, this framework extends naturally to weaving and supports control law design. Additionally, a method for systematically accounting for wall crossings is introduced and validated experimentally through the deposition of two intersecting weaving walls.