WAAM Torch
Relation: National Science Foundation - HAMMER
Role: Mechanical Design Engineer
Skills: Mechanical design, CAD (SolidWorks), machining, lathe, milling, thread specification, tolerance control, prototyping, WAAM systems
Background:
The original wire-arc torch component deformed
during disassembly, limiting serviceability and risking damage to the system.
The goal of this redesign was to improve Z-axis clearance, preserve the
existing diffuser interface, and enable repeatable removal without inducing
deformation.
Direct contributions:
●
Redesigned torch geometry to
reduce overall length and increase available Z travel
●
Preserved diffuser interface using
a 1/2-20 UNF external thread
●
Added axial relief slits and
wrench flats to prevent torsional and bending stress during removal
●
Created detailed CAD and
manufacturing drawings
●
Machined the torch from copper rod
using band saw, lathe, and mill operations
●
Performed fit checks with the
diffuser and validated through repeated assembly cycles
Outcomes:
The redesigned torch has been operating in the
WAAM system with no observed failures. Service is faster, and removal no longer
causes deformation.
