Invention Reference Number
This technology enables additive manufacturing with controllable bead width using a strip-based deposition approach. It addresses limitations in conventional strip welding and additive processes that restrict feature resolution or require manual rework. By dynamically varying the effective deposition width during fabrication, the method supports near-net-shape production of large or complex metal components while reducing defects, gaps, and post-processing. The approach improves manufacturing flexibility and efficiency in applications where conventional casting or fixed-width welding methods are costly, slow, or geometrically constrained.
Description
Traditional strip-based welding and additive manufacturing methods offer high deposition rates but are typically limited to fixed bead widths determined by the electrode geometry. This technology overcomes that limitation by introducing controlled variation in bead width during deposition, allowing a single strip configuration to produce features of differing resolution within the same build.
The process leverages coordinated motion and orientation control of the strip electrode relative to the direction of travel and the workpiece. These controlled adjustments enable both wider and narrower deposition regions without changing consumables. As a result, manufacturers can create complex geometries, transition smoothly between feature sizes, and fill gaps that would otherwise require secondary manual welding or grinding.
The method is applicable to additive manufacturing of new components as well as enhancement or repair of existing parts, including cylindrical or layered builds where traditional approaches leave discontinuities. The result is improved geometric fidelity, reduced labor, and greater consistency across large-scale metal fabrication workflows.
Benefits
- Enables variable feature resolution without changing electrode hardware
- Reduces manual rework associated with gaps or overlapping welds
- Supports near-net-shape fabrication of complex metal components
- Improves process flexibility for large-scale additive manufacturing
Applications and Industries
- Large-scale metal additive manufacturing
- Industrial welding and cladding operations
- Heavy equipment and infrastructure components
- Advanced manufacturing and fabrication facilities
Contact
To learn more about this technology, email partnerships@ornl.gov or call 865-574-1051.
