Mobile WAAM printer: design, optimization and experimental evaluation

This research presents the design and development of an autonomous climbing robot aimed at overcoming mobility challenges in complex and dynamic environments. A key innovation is the integration of Wire Arc Additive Manufacturing (WAAM), enabling the robot to autonomously fabricate structural, load-bearing beams that serve as climbing paths. This approach allows for vertical movement and addresses the limitations of traditional stationary 3D printing systems. The robot follows a cycle of printing structural profiles with coupling holes, anchoring onto them, and printing the next segment, enabling continuous ascent along the Z-axis. A major focus of the work is a novel torch compensation system that synchronizes the motion of the WAAM torch with the robot’s legs during simultaneous printing and climbing. This coordination ensures deposition accuracy and structural integrity on dynamically changing surfaces and compensates for misalignments caused by motion and geometry variations. To manage uncertainties in positioning and anchoring, an AI-driven control framework was developed. This includes IMU-based self balancing for stability, Bayesian optimization for detecting coupling holes under uncertainty, and real-time trajectory adjustment for precise coordination between locomotion and printing. The project began with a pre-existing mechanical design that included core components like the legs and frame, along with basic leg movement and homing functions. Initial efforts focused on studying this system and identifying improvements. Building on this foundation, the robot was completed through the integration of WAAM capabilities and synchronized torch motion. The result is a refined, fully autonomous system capable of continuous vertical fabrication and adaptive mobility.