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Additive Manufacturing CAM

Laser Wire DED & Hot-Wire Trajectory Calculator

Model wire feed rate ($v_w$), laser power ($P_L$), hot-wire Joule preheating ($I_{ ext{hw}}$), wire-to-melt-pool bridge stability, and 5-axis wire feeding vector orientation.

Process Parameters & Inputs

Fiber / diode laser continuous power output.
Linear CNC / robot travel velocity along toolpath trajectory.
Wire push velocity through precision guide nozzle.
Joule preheating current (0A = cold wire; 30-70A = hot wire).
Angle between incoming wire and substrate surface.

Calculated Engineering Metrics

Bead Width (W)
3.8mm
Bead Layer Height (H)
1.4mm
Deposition Rate
0.96kg/h
Transfer Bridge Mode
Stable(Liquid Bridge)

Toolpath & Geometry Simulation

Engineering Reference:
→ Read the Laser Wire DED & Hot-Wire Additive Vector CAM Prepress Guide

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Engineering Principles & Formula Reference

Laser Wire Direct Energy Deposition (L-DED-W) achieves 100% material capture efficiency and zero powder porosity by feeding solid wire directly into a laser-induced melt pool under inert argon shielding.

Mass Balance & Bead Geometry Relations

Assuming parabolic or circular bead cross-section with wire feed speed v_w and travel speed v_t:

A_bead = rac{\pi d_w^2}{4} \cdot rac{v_w}{v_t}
W_bead pprox 1.8 \cdot d_w \cdot \left( rac{v_w}{v_t} ight)^{0.38} \cdot \left( rac{P_L}{2000} ight)^{0.25}
H_bead pprox rac{A_bead}{0.68 \cdot W_bead}

Hot-wire resistive preheating (I_hw) boosts deposition rates by 40%–80% for the same laser power, minimizing thermal distortion in large titanium and nickel superalloy builds.