Dynamic Welding Program Planning for Additive Layer Fusion

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Solution Overview

Problem

Existing additive manufacturing techniques face challenges in maintaining desired adhesion between layers and integrity of the part, particularly with materials like metal, due to rapid heating and cooling, leading to issues such as lack of fusion and warping.

Innovation Solution

An additive manufacturing system that uses temperature sensors to dynamically adjust welding-type programs based on measured temperature, transitioning between different heat output modes to regulate heat input and ensure suitable fusion between layers, without requiring preheating devices or complex path planning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional additive manufacturing techniques are used with metal materials, then the part can be built up layer by layer, but the rapid heating and cooling causes lack of fusion and warping between layers

Engineering Contradiction:

Improvelayer adhesionVSAvoidwarping and lack of fusion

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The system dynamically transitions between different welding-type programs (first program with higher heat output, second program with lower heat output) based on real-time temperature monitoring. This dynamic adjustment allows the system to adapt heat input to current thermal conditions, ensuring proper fusion when temperature is low and preventing warping when temperature is high, thereby resolving the contradiction between layer adhesion and warping prevention

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system employs temperature sensors to continuously monitor the part temperature and uses this feedback to automatically select appropriate welding-type programs. The feedback loop enables real-time control of heat input, adjusting parameters such as wire feed speed and travel speed based on measured temperature, thus preventing both lack of fusion and warping

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If preheating devices or complex path planning are used to improve layer adhesion, then fusion between layers improves, but the device complexity and fabrication time increase

Engineering Contradiction:

Improvefusion between layersVSAvoidpreheating devices and path planning

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system uses the part itself as the heat source by utilizing the inherent heat generated during the additive manufacturing process. The controlled transitions between welding programs allow the part to maintain its own temperature within optimal ranges, eliminating the need for external preheating devices while ensuring proper fusion between layers

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system changes operational parameters (wire feed speed, travel speed, heat output) by transitioning between different welding-type programs based on temperature conditions. This parameter adjustment approach achieves consistent fusion without requiring complex path planning or additional hardware, simplifying the overall system while maintaining manufacturing precision

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enhances layer adhesion and reduces warping by effectively controlling heat input, ensuring consistent fusion and improved part integrity while maintaining fabrication speed and flexibility.

Implementation Method 1

An additive manufacturing system uses temperature sensors to dynamically adjust welding-type programs based on measured temperature

Methodology Applied

Scientific EffectTemperature sensing:

Implementation Method 2

transitioning between different heat output modes to regulate heat input and ensure suitable fusion between layers

Methodology Applied

Scientific EffectWelding heat input control:

Data Source

PatentUS12583045B2Systems and methods for dynamic additive manufacturing welding program planning

Publication Date: 2026.03.24 ILLINOIS TOOL WORKS INC

AI summary

Disclosed is a welding system configured to perform additive manufacturing, particularly by employing an additive manufacturing tool to build up a part by employing welding-type programs. In some examples, control circuitry controls the additive manufacturing tool to operate in a first welding-type program of a plurality of welding-type programs in response to a determination that the measured temperature is below a first threshold temperature of one or more threshold temperatures, and control the additive manufacturing tool to operate in a second welding-type program of the plurality of welding-type programs in response to a determination that the measured temperature is above the first threshold temperature.