Wire arc additive manufacturing (WAAM) is emerging as the main additive manufacturing (AM) technology used to produce medium-to-large-sized thin-walled parts (order of magnitude: 1 m) at lower cost. To manufacture a part with this technology, the path planning strategy used is the 2.5D. This strategy consists in slicing a 3D model into different planar layers parallel to each other. The use of this strategy limits the complexity of the topologies achievable in WAAM, especially those with large variations in curvature. It also involves several start/stops of the arc as it passes from one layer to another, which induces transient phenomena in which the control of the supply of energy and matter is complex. In this article, a new manufacturing strategy to minimize the start/stop phases of the arc to one unique cycle is presented. The goal of this strategy, called “Continuous Three-dimensional Path Planning” (CTPP) is to generate a continuous trajectory in spiral form for closed-loop thin parts. An adaptive wire speed coupled with a constant travel speed allow a modulation of the deposition geometry that ensures a continuous supply of energy and material throughout the manufacturing process. Using the 5-axis strategy coupled with CTPP allows the manufacture of closed parts with a procedure to determine the optimum closing area and parts on non-planar substrates useful for adding functionalities to an existing structure. Two geometries based on continuous manufacturing with WAAM technology are presented to validate this approach. The manufacturing of these parts with CTPP and several numerical evaluations have shown the reliability of this strategy and its capacity to produce complex new shapes with a good geometrical restitution, difficult or impossible to reach today using 2.5D with WAAM technology.

电弧增材制造（WAAM）逐渐成为主要的增材制造（AM）技术，用于以较低的成本生产中型到大型的薄壁零件（数量级：1 m）。为了使用该技术制造零件，使用的路径规划策略是2.5D。该策略包括将3D模型切成彼此平行的不同平面层。这种策略的使用限制了WAAM中可实现的拓扑的复杂性，尤其是曲率变化较大的拓扑。当电弧从一层传递到另一层时，它还涉及到电弧的多次起/停，这会引起瞬态现象，在瞬态现象中，能量和物质的供应控制非常复杂。在本文中，提出了一种新的制造策略，可将电弧的开始/停止阶段减少到一个唯一的周期。称为“连续三维路径规划”（CTPP）的该策略的目标是为闭环薄零件生成螺旋形式的连续轨迹。自适应的线速度与恒定的行进速度相结合，可以调节沉积几何形状，从而确保在整个制造过程中持续提供能量和材料。将5轴策略与CTPP结合使用，可以通过确定最佳闭合区域的过程制造非闭合零件，并在非平面基板上制造零件，从而对现有结构增加功能。提出了两种基于WAAM技术进行连续制造的几何形状，以验证该方法。