Dhanbad: The Indian Institute of Technology (Indian School of Mines), Dhanbad (IIT-ISM), has announced a major breakthrough in additive manufacturing (AM) with the development of a twin-wire 3D printing system that integrates in-situ alloying capabilities.
This innovative setup is a testament to India’s growing expertise in AM technology and is expected to significantly enhance the efficiency and sustainability of metal fabrication processes.
Additive manufacturing, particularly in the field of metal printing, has revolutionized the production of complex components by allowing for the creation of intricate metal structures with minimal lead times. Among the various AM techniques, Wire Arc Additive Manufacturing (WAAM) has emerged as a popular choice due to its high deposition rates and cost-effectiveness, particularly in industrial applications.
The newly developed twin-wire setup at IIT-ISM combines cutting-edge technology with high precision. The system is powered by a Yaskawa six-axis industrial robot, which ensures accuracy throughout the deposition process. Key components of the setup include:
Manipulator: Ensures the precise movement and handling of the deposition process.
Controller (YRC 1000): Coordinates the robot’s motion and welding operations.
Programming Teach/Play Pendant: Defines torch paths for accurate deposition.
Manipulator Cables: Ensure smooth communication between system components.
Gas Tungsten Arc Welding (GTAW) Power Source: Provides superior control for metal deposition quality.
Wire Feed System: Facilitates in-situ alloying, enhancing the material properties of the fabricated components.
The system’s performance is further enhanced by the MOTOMAN robot-assisted software, which ensures high-precision deposition, leading to superior mechanical properties in the final products.
Research Impact and Industrial Applications
This pioneering project, funded by the Science and Engineering Research Board (SERB) under the Government of India (Project Code: EEQ/2021/000184), marks a significant advancement in AM technology. The research has been published in internationally recognized journals, showcasing the system’s effectiveness. Moreover, the innovative design is under evaluation for patent approval, reinforcing IIT-ISM’s role as a leader in the field of advanced manufacturing.
IIT-ISM is actively researching multi-material components for a wide range of industries, including aerospace, automotive, and heavy machinery repair. The ability to fabricate and repair critical components with this advanced setup offers immense potential for the manufacturing and maintenance sectors, offering faster, more cost-effective solutions.
Industry Collaboration and Knowledge Sharing
IIT-ISM is dedicated to fostering collaboration and knowledge-sharing. Its Advanced Manufacturing Lab is open to students, entrepreneurs, and industry professionals, offering opportunities to explore the state-of-the-art AM setup. Scheduled visits can be arranged via email, as listed on the institute’s website.
One of the main goals of this initiative is to raise awareness among the youth and entrepreneurs of Jharkhand, encouraging technological advancement and industrial growth in the region. By showcasing the potential of in-situ alloying and AM, IIT-ISM aims to inspire future innovations and foster collaboration in the field of advanced manufacturing technologies.
With this groundbreaking development, IIT-ISM is setting the stage for a more efficient, sustainable, and technologically advanced future in metal fabrication.
