Introduction[edit | edit source]
Wire arc additive manufacturing (WAAM) is a process that allows for directed deposition of metal alloys, iimplementing a gas metal arc welding (GMAW) format to "print" 3D structures out of metals. The Mini Metal 3D Printer allows for screening of WAAM process parameters, new alloys, and , all for a low cost and open source design.
Safety[edit | edit source]
As with any welding process, hot work and electrical safety precautions must be taken. There exists risk for burns and electrical shock while interfacing with weld work pieces.
To avoid burns, ensure that the work piece has had ample time to cool (via active cooling or air cooling) before touching the work piece. Additionally, work gloves (cotton or leather) can be work to avoid burning hands.
To avoid electrical shock, ensure that the welder is not on while mounting/un-mounting a work piece from the print bed of the WAAM printer.
Equipment or Bill of Materials[edit | edit source]
| Item | Quantity/Length (#/ft) | Cost |
|---|---|---|
| BenBox CNC frame | 1 | |
| Millermatic 190 MIG welder | 1 | |
| Millermatic 190 compatible electrode/gas cable | 1 | |
| Welding nozzle assembly | 1 | |
| Argon compressed gas cylinder | 1 | |
| Ar compressed gas regulator | 1 | |
| Compressed gas hose | 1 | |
| Welding nozzle assembly | 1 | |
| Arduino Mega board | 1 | |
| Beagle Bone board | 1 | |
| RAMPs board | 1 | |
| RAMPS drivers | 4 | |
| CAT-5 network cord | 1 | |
| USB cord | 2 | |
| Stepper/driver wires | 4 | |
| Grounding cable | 1 | |
| Trigger circuit leads | 2 | |
| Metal box to shield electronics | 1 | |
| Extruded aluminum bar | 1 | |
| Extruded aluminum bar fasteners | 4 | |
| Aluminum plate | 1 | |
| PVC tubing | 10 | |
| Water pump | 1 | |
| NPT nylon elbow nipples | 2 | |
| Bolt for locating spool | 1 | |
| Nylon tubing | 0.5 | |
| Wire feeder assembly | 1 | |
| Heat exchanger print bed | 1 |
Calibration & Tolerances[edit | edit source]
The following welding parameters were optimized for 4047 aluminum, but have been found to print 5356 aluminum with the same weld transfer mechanisms. Note that the gas flow rate for each setting was approximately 20 LPH of 99.99% Argon.
| Weld Parameter | Spray Transfer | Short Circuit Transfer |
|---|---|---|
| Miller 190 Power Setting | 7 | 3 |
| Wire Feed Rate (mm/s) | 150 | 150 |
| Extruded Wire/Print length ratio (mm/mm) | 5/1 | 5/1 |
| Print Head Travel Velocity (mm/s) | 30 | 50 |
Operation & Procedure[edit | edit source]
Shutdown[edit | edit source]
References[edit | edit source]
