Wire-arc directed energy deposition of metal using a tendon-driven soft robotic gun: prototyping and conceptual validation

Abstract

Most directed energy deposition (DED) implementations employ a rigid end effector to deposit material layer-by-layer, which is insufficient in cases with space constraints. To enhance the flexibility, this paper proposes a novel soft-robotic gun (SRG) based DED technology. The ideology is to replace the rigid weld gun with a tendon-driven omnidirectional-steering continuum manipulator, which a computer can numerically control. To this end, both requirements and concepts of the SRG-DED are introduced. A prototype system is designed and implemented before dedicated kinematic modelling and trajectory planning mechanisms are presented. As demonstrated by the experimental results, the developed trajectory planning algorithm improves the computational efficiency of tendon variables and enhances the consistency of trajectory tracking. The prototype system can deposit a complex path on an inclined substrate and fabricate a thin-wall component within a pipeline. The validation work confirms the feasibility and applicability of the prototype system for metal additive manufacturing applications.

Keywords

• Wire-arc directed energy deposition
• soft robot
• omnidirectional metal deposition
• kinematic modelling
• trajectory planning