Abstract
This work presents a machine-vision–based measurement and control framework for laser wire directed energy deposition (LWDED) processes. A visible-light camera system is used to capture meltpool images, from which a novel vision algorithm extracts the wire–meltpool interface location. By utilizing a camera that is rigidly mounted to the deposition head, the vision algorithm provides a relative measurement of the distance between the nozzle tip and the workpiece, also referred to as wire stickout. A proportional-derivative (PD) control strategy is implemented using the measured stickout as feedback to adjust deposition feedrate. Results show that the control system successfully compensates for improper layer height increments, enabling thin-wall builds to consistently reach target geometry.
Recommended Citation
B. McLain et al., "Machine Vision for In Situ Measurement and Control of Wire Stickout in LWDED Process," Machines, vol. 14, no. 5, article no. 534, MDPI, May 2026.
The definitive version is available at https://doi.org/10.3390/machines14050534
Department(s)
Mechanical and Aerospace Engineering
Publication Status
Open Access
Keywords and Phrases
laser wire deposition; machine vision; stability; wire stickout
International Standard Serial Number (ISSN)
2075-1702
Document Type
Article - Journal
Document Version
Final Version
File Type
text
Language(s)
English
Rights
© 2026 The Authors, All rights reserved.
Creative Commons Licensing
This work is licensed under a Creative Commons Attribution 4.0 License.
Publication Date
01 May 2026
