Showing 18 results for Author: Joshua E. Vaughan
Sep, 2026
Journal
Incorporating multiple robotic manipulators into large-scale manufacturing systems enhances production efficiency and expands manufacturing capabilities beyond those of single-robot systems. Workpiece positioners in robotic manufacturing have demonstrated significant benefits for process optimization, but coordination strategies for multi-robot systems with shared position…
Feb, 2026
Journal
This article introduces the Future Foundries platform developed at Oak Ridge National Laboratory, a first-generation research system designed to demonstrate convergent manufacturing. Convergent manufacturing brings together additive, subtractive, and transformative processes in a digitally interconnected environment to enable end-to-end production workflows. By linking tra…
Nov, 2025
Journal
Oak Ridge National Laboratory (ORNL) has developed a highly automated manufacturing process for thermoplastic composites that combines the benefits of Additive Manufacturing and Compression Molding (AM-CM) to produce high-performance functional composite structures at automotive production rates. The AM-CM process creates highly precise preforms by additively placing extru…
Jul, 2025
ORNL Report
Mar, 2025
Journal
Both commercial and research applications of wire arc additive manufacturing (WAAM) have seen considerable growth in the additive manufacturing of metallic components. However, there remains a clear lack of a unified paradigm for toolpath generation when slicing parts for WAAM deposition. Existing toolpath generation options typically lack the appropriate features to accou…
Mar, 2025
Journal
Additive manufacturing (AM) of large objects has, over the last decade, required the scaling of existing material extrusion processes. The current generation of large-scale printers are primarily gantry robots with high-throughput extrusion systems. With workspaces approaching 50 m3, these printers have pushed the boundaries of achievable print volume while allowing the ut…
Nov, 2024
Journal
Laser-wire metal additive manufacturing (AM) is one of the ideal direct energy deposition (DED) processes for creating large-scale parts with a medium level of complexity. However, the DED process involves complex thermal signatures and wide length scales making the fabrication of realistic AM components and part qualification often reliant on experimental trial-and-error…
Aug, 2024
ORNL Report
User Guide for Wolf Branch of ORNL Slicer, the slicer for Wire Arc Additive Manufacuring (WAAM).
Nov, 2023
Journal
Conventional robotic wire arc additive manufacturing technologies enable the rapid production of moderate-sized components using low-cost wire feedstocks and robotic welding systems. Efforts to date have primarily focused on single robot solutions. However, new configurations are possible with coordination of multiple robots and multi-degree of freedom positioners. This pa…
Nov, 2023
Journal
Wire-arc direct energy deposition (wire-arc DED) has been developed to manufacture large-scale metal products with high deposition rates, low material cost, and high material efficiency. However, dynamically varying printing conditions and complex geometries frequently lead to unfavorable part distortions during and after printing which are magnified as part sizes increase…
Nov, 2023
Journal
Residual stresses affect the performance and reliability of most manufactured goods and are prevalent in casting, welding, and additive manufacturing (AM, 3D printing). Residual stresses are associated with plastic strain gradients accrued due to transient thermal stress. Complex thermal conditions in AM produce similarly complex residual stress patterns. However, measurin…