High-precision thin wall fabrication of aluminum alloys using a wire-laser metal 3D printer with laser power control based on a scaling law

High-quality fabrication from aluminum alloys using a wire-laser metal 3D printer requires precise dimensional control, particularly uniform wall thickness. However, heat accumulation during the process poses a significant challenge. The present study aims to develop and validate a laser power control strategy that compensates for the effects of heat accumulation to achieve high-precision thickness control. To this end, an empirical model was developed based on a scaling law between build height and laser power. Laser power was then adjusted as a function of build height according to the model’s predictions. As a result, the proposed control strategy successfully maintained the target wall thicknesses (2.70, 2.80, and 2.90 mm), achieving an average deviation of 0.06 mm and a standard deviation of 0.11 mm, demonstrating effective dimensional control. Furthermore, optimizing the wire feeding conditions significantly reduced surface waviness—an issue that emerged after achieving dimensional control. In conclusion, this study presents a practical approach for high-precision dimensional control through model-based regulation and emphasizes the importance of integrated thermal input and material supply management for high-quality fabrication.