Reducing Delivery Times by Utilising On-Site Wire Arc Additive Manufacturing with Digital-Twin Methods
The increasing demand for smaller batch sizes and mass customisation in production poses considerable challenges to logistics and manufacturing efficiency. Conventional methodologies are unable to address the need for expeditious, cost-effective distribution of premium-quality products tailored to i...
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MDPI AG
2025-06-01
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| Series: | Computers |
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| author | Stefanie Sell Kevin Villani Marc Stautner |
| author_facet | Stefanie Sell Kevin Villani Marc Stautner |
| author_sort | Stefanie Sell |
| collection | DOAJ |
| description | The increasing demand for smaller batch sizes and mass customisation in production poses considerable challenges to logistics and manufacturing efficiency. Conventional methodologies are unable to address the need for expeditious, cost-effective distribution of premium-quality products tailored to individual specifications. Additionally, the reliability and resilience of global logistics chains are increasingly under pressure. Additive manufacturing is regarded as a potentially viable solution to these problems, as it enables on-demand, on-site production, with reduced resource usage in production. Nevertheless, there are still significant challenges to be addressed, including the assurance of product quality and the optimisation of production processes with respect to time and resource efficiency. This article examines the potential of integrating digital twin methodologies to establish a fully digital and efficient process chain for on-site additive manufacturing. This study focuses on wire arc additive manufacturing (WAAM), a technology that has been successfully implemented in the on-site production of naval ship propellers and excavator parts. The proposed approach aims to enhance process planning efficiency, reduce material and energy consumption, and minimise the expertise required for operational deployment by leveraging digital twin methodologies. The present paper details the current state of research in this domain and outlines a vision for a fully virtualised process chain, highlighting the transformative potential of digital twin technologies in advancing on-site additive manufacturing. In this context, various aspects and components of a digital twin framework for wire arc additive manufacturing are examined regarding their necessity and applicability. The overarching objective of this paper is to conduct a preliminary investigation for the implementation and further development of a comprehensive DT framework for WAAM. Utilising a real-world sample, current already available process steps are validated and actual missing technical solutions are pointed out. |
| format | Article |
| id | doaj-art-f89ddfd8f0b34d7bafc7a66516a84d90 |
| institution | OA Journals |
| issn | 2073-431X |
| language | English |
| publishDate | 2025-06-01 |
| publisher | MDPI AG |
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| spelling | doaj-art-f89ddfd8f0b34d7bafc7a66516a84d902025-08-20T02:24:25ZengMDPI AGComputers2073-431X2025-06-0114622110.3390/computers14060221Reducing Delivery Times by Utilising On-Site Wire Arc Additive Manufacturing with Digital-Twin MethodsStefanie Sell0Kevin Villani1Marc Stautner2Institute for Mechanical Engineering, Ruhr West University of Applied Sciences, 45479 Muelheim an der Ruhr, GermanyInstitute for Mechanical Engineering, Ruhr West University of Applied Sciences, 45479 Muelheim an der Ruhr, GermanyInstitute for Mechanical Engineering, Ruhr West University of Applied Sciences, 45479 Muelheim an der Ruhr, GermanyThe increasing demand for smaller batch sizes and mass customisation in production poses considerable challenges to logistics and manufacturing efficiency. Conventional methodologies are unable to address the need for expeditious, cost-effective distribution of premium-quality products tailored to individual specifications. Additionally, the reliability and resilience of global logistics chains are increasingly under pressure. Additive manufacturing is regarded as a potentially viable solution to these problems, as it enables on-demand, on-site production, with reduced resource usage in production. Nevertheless, there are still significant challenges to be addressed, including the assurance of product quality and the optimisation of production processes with respect to time and resource efficiency. This article examines the potential of integrating digital twin methodologies to establish a fully digital and efficient process chain for on-site additive manufacturing. This study focuses on wire arc additive manufacturing (WAAM), a technology that has been successfully implemented in the on-site production of naval ship propellers and excavator parts. The proposed approach aims to enhance process planning efficiency, reduce material and energy consumption, and minimise the expertise required for operational deployment by leveraging digital twin methodologies. The present paper details the current state of research in this domain and outlines a vision for a fully virtualised process chain, highlighting the transformative potential of digital twin technologies in advancing on-site additive manufacturing. In this context, various aspects and components of a digital twin framework for wire arc additive manufacturing are examined regarding their necessity and applicability. The overarching objective of this paper is to conduct a preliminary investigation for the implementation and further development of a comprehensive DT framework for WAAM. Utilising a real-world sample, current already available process steps are validated and actual missing technical solutions are pointed out.https://www.mdpi.com/2073-431X/14/6/221additive manufacturing (AM)directed energy deposition (DED)wire arc additive manufacturing (WAAM)digital twin (DT) |
| spellingShingle | Stefanie Sell Kevin Villani Marc Stautner Reducing Delivery Times by Utilising On-Site Wire Arc Additive Manufacturing with Digital-Twin Methods Computers additive manufacturing (AM) directed energy deposition (DED) wire arc additive manufacturing (WAAM) digital twin (DT) |
| title | Reducing Delivery Times by Utilising On-Site Wire Arc Additive Manufacturing with Digital-Twin Methods |
| title_full | Reducing Delivery Times by Utilising On-Site Wire Arc Additive Manufacturing with Digital-Twin Methods |
| title_fullStr | Reducing Delivery Times by Utilising On-Site Wire Arc Additive Manufacturing with Digital-Twin Methods |
| title_full_unstemmed | Reducing Delivery Times by Utilising On-Site Wire Arc Additive Manufacturing with Digital-Twin Methods |
| title_short | Reducing Delivery Times by Utilising On-Site Wire Arc Additive Manufacturing with Digital-Twin Methods |
| title_sort | reducing delivery times by utilising on site wire arc additive manufacturing with digital twin methods |
| topic | additive manufacturing (AM) directed energy deposition (DED) wire arc additive manufacturing (WAAM) digital twin (DT) |
| url | https://www.mdpi.com/2073-431X/14/6/221 |
| work_keys_str_mv | AT stefaniesell reducingdeliverytimesbyutilisingonsitewirearcadditivemanufacturingwithdigitaltwinmethods AT kevinvillani reducingdeliverytimesbyutilisingonsitewirearcadditivemanufacturingwithdigitaltwinmethods AT marcstautner reducingdeliverytimesbyutilisingonsitewirearcadditivemanufacturingwithdigitaltwinmethods |