Purpose This study aims to develop and demonstrate a deposition framework for the implementation of a region-based adaptive slicing strategy for the Tungsten Inert Gas (TIG) welding-based additive manufacturing system. The present study demonstrates a deposition framework for implementing a novel region-based adaptive slicing strategy termed as Fast Interior and Accurate Exterior with Constant Layer Height (FIAECLH). Design/methodology/approach The mentioned framework has been developed by performing experiments using the design of experiments and analyzing the experimental data. Analysis results have been used to obtain the mathematical function to integrate customization in the process. The paper, in the end, demonstrates the FIAECLH framework for implementing region-based adaptive slicing strategy on the hardware level. Findings The study showcase a new way of implementing the region-based adaptive slicing strategy to arc-based metal additive manufacturing. The study articulating a new strategy for its implementation in all types of wire and arc additive manufacturing processes. Originality/value Wire-arc-based technology has the potential to deliver cost-effective solutions for metal additive manufacturing. The research on arc welding-based processes is being carried out in different dimensions. To deposit parts with complex geometry and better dimensional accuracy implementation of a novel region-based adaptive slicing strategy for the arc-based additive manufacturing process is an essential task. The successful implementation of an adaptive slicing strategy would ease the fabrication of complex geometry in less time. This paper accomplishes this need of implementing a region-based adaptive slicing strategy as no experimental investigation has been reported for the TIG-based additive manufacturing process.

The arc welding-based additive manufacturing technology is in its developing state. This technology can be utilized to produce free-form metallic structures for the aerospace and biomedical industry. The current article presents the design of semi-automatic gas tungsten arc welding-based additive manufacturing system for fabricating thin-walled metallic structures. This study aims to analyze the effect of process variables on the output parameters, such as deposition width and deposition height. The set of experiments were performed based on the design developed by Taguchi method. The experimental data have been analyzed to study the effect of the significant process parameters like current, torch speed, wire feeding speed and torch angle. The optimization of the significant process parameters has been done to ensure thin-walled deposition with minimum wall thickness and better geometric characteristics. Experimental results showed that as the angle of inclination increases the deposition width increases and the deposition height decreases. The surface appearance of the bead sample deposited at a different angle of inclination was investigated. The thickness of the wall obtained in this study was found to be the lowest wall thickness achieved by the arc welding-based additive manufacturing process deploying filler material of 1.2 mm diameter.

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