Design and Fabrication of a Pre-Calibrated Mount/Jig and a Fixed Calibration Fixture for WAAM Thermal Camera

Wire Arc Additive Manufacturing (WAAM) is a promising technology for fabricating large metal components, but consistent thermal monitoring is challenging due to camera positioning variability. This project addresses that issue by developing two key systems: a pre-calibrated mounting jig and a fixed calibration fixture.

The partner organization, which operates a WAAM system, requires precise camera alignment to capture thermal data for process optimization and defect detection. The proposed pre-calibrated jig offers an operator-friendly, adjustable mount with linear scales, quick-release mechanisms, and marked focal distances, enabling rapid repositioning while maintaining accuracy. The fixed calibration fixture will attach to the robot arm, ensuring consistent distance and orientation between the thermal camera and wire tip for each setup. Both solutions involve CAD modeling, technical drawing, and fabrication via additive manufacturing, ensuring precision and integration with the existing setup.

The anticipated benefits of this project include improved process repeatability, reduced calibration time, and enhanced data reliability during WAAM monitoring. For the partner organization, this streamlines AM workflows, enhances thermal control, and supports more robust and scalable WAAM solutions. Socially, the project fosters workforce upskilling in digital fabrication, expansion of professional network, and aligning with broader advanced manufacturing goals.

Faculty Supervisor:

Osezua Ibhadode

Student:

Partner:

InnoTech Alberta

Discipline:

Engineering

Sector:

Professional, scientific and technical services

University:

University of Alberta

Program: