Additive Manufacturing & Robotic CAM
WAAM & DED-Wire Deposition Calculator
Compute Wire Arc Additive Manufacturing (WAAM) bead width, height, center-to-center overlap pitch (Flat Top Overlapping Model / FTOM), layer step-up increment, and linear heat input.
1. Input Parameters
Feed wire diameter (e.g. ER70S-6, Ti-6Al-4V, Al 4043).
Linear wire drive speed into the melt pool.
Linear torch movement speed along the deposition path.
Arc welding operating voltage.
Operating welding current.
2. Calculation Results
Single Bead Width (W)
6.80 mm
Single Bead Height (H)
2.45 mm
Rec. Center Overlap (d_o)
4.53 mm (66.7%)
Layer Step Increment (Δz)
2.05 mm
3. Geometric Visualizer
Tooling & Vector Prepress Engineering Notes
Flat Top Overlapping Model (FTOM): Multi-bead WAAM preforms require continuous planar top surfaces to prevent valley porosity in successive vertical layers. The optimal center-to-center bead pitch is mathematically d_o = 0.667 · W (66.7% of bead width). Spacing > 0.738 · W causes deep valleys, while < 0.60 · W causes excessive central humping.
Linear Heat Input: Calculated via E_L = η · (U · I) / TS (with arc efficiency η ≈ 0.80 for GMAW/CMT). Controlling interpass temperature below 150°C prevents thermal distortion and coarse grain embrittlement.