Thin Metal Surface Formation

Contemporary robotic metal fabrication is limited by either the 2.5D conditions of surface forming or the prohibitive time and cost of additive manufacturing. This research introduces a novel sheet metal fabrication technique that integrates Incremental Sheet Forming (ISF) and Wire-Arc Additive Manufacturing (WAAM) to create complex and intricate architectural surfaces. Through a series of technical experiments and prototypes, this paper evaluates the feasibility of robotic welding and 3D metal printing on pre-formed 2.5D mild steel surfaces less than 1mm thick. It identifies key parameters in robotic 6-axis programming, CMT Cycle Step welding, and their relationship with material thicknesses. Additionally, the paper demonstrates hardware and workflow development that support this innovation. This hybrid approach aims to enhance the structural performance and complexity of thin metal surfaces while generating new design languages characterised by highly detailed patterns and distinctive material characteristics, reducing material usage and fabrication waste in architectural fabrication. The paper suggests further research into design implications for large-scale architectural applications.<p></p>