In-Situ visual reconstruction of strut profiles in pulsed wire arc additive manufacturing of lattice structures

The wire arc additive manufacturing (WAAM) process often results in geometric inaccuracies in the produced struts, highlighting the need for in-situ monitoring. Industrial cameras struggle to capture accurate images due to interference from arc light and metal radiation. This study introduces a real-time visual reconstruction method that leverages regions of interest (ROI) to enhance profile accuracy. Initially, the melt pool is analyzed and segmented from a series of frames to establish an initial strut profile. This profile then serves as the ROI for segmenting the solidified weld bead regions, yielding a more precise strut profile. Comparative analysis shows that the proposed method achieves a high Intersection Over Union (IOU) score of 0.911 and an Average Symmetric Surface Distance (ASD) error of 0.355 mm, demonstrating both accuracy and robustness. Additionally, the inclination angle and diameter are extracted from the reconstructed profiles.