Restriction-free Additive Arc Welding

  Robot with Component Copyright: © IGMR

Project State


  Pictogram Multidirectional Additive Manufacturing with a Robot Copyright: © RWTH

Multidirectional additive manufacturing using arc welding with eccentric wire feeding offers great potential for additive manufacturing of large structural components. The DFG-funded project overcomes challenges of a kinematics and welding.

Within the framework of the DFG-funded project Restriction-free Additive Arc Welding, the IGMR together with the Welding and Joining Institute at RWTH Aachen University is researching the possibilities and methods of additive manufacturing by arc welding without restrictions due to kinematics. Core element of the developments is the fixation of the welding head in the working space of a robot with at least six degrees of freedom. Challenges regarding path and trajectory planning as well as welding parameters are addressed in the project.



Additive manufacturing with the arc welding process is usually restricted in its design freedom, which is caused by the configuration of the kinematic setup. A movement and rotation of the welding head creates problems for the process with the handling of the welding wire and the carrying along of the welding periphery. Furthermore, due to the movement of the welding head, the weld pool position can only be guaranteed in one set-up direction.
This motivated this project, in which the welding head is fixed in space and the component is manipulated without restriction by a robot under the welding head.


The aim of the project is to develop and validate algorithms and methods for constraint-free path and trajectory planning for multidirectional additive manufacturing. In addition, the influence of both, welding parameters and kinematic parameters, will be researched and adapted in an online planning in the process.
The aim is to produce near-net-shape components with improved properties and a high degree of design freedom.


In the project, the classic motion planning of additive manufacturing was expanded and slicing, path planning and trajectory planning were tailored to multidirectional additive manufacturing. The main challenges are the collision-free production of multidirectional components and the corresponding slicing, the accessibility of all path elements and the continuous filling of surfaces in the context of path planning as well as the optimization of the trajectory and the welding parameters to ensure the executability and optimization of the component properties.


The project is carried out in cooperation with the Welding and Joining Institute of RWTH Aachen University.




Multidirectional Additive Manufacturing