Description:HYBRID WIRE ARC ADDITIVE MANUFACTURING (WAAM) SYSTEM AND METHOD THEROF
FIELD OF THE INVENTION
[0001] The present invention relates to the field of additive manufacturing and, more particularly, to a hybrid manufacturing system and method that combines directed energy deposition with an integrated mechanical surface enhancement process.
BACKGROUND OF THE INVENTION
[0002] In the evolving landscape of manufacturing technologies, additive manufacturing has emerged as a transformative approach for producing metal components with complex geometries and reduced material waste. This layer-by-layer fabrication process has found growing acceptance across various industrial sectors due to its potential to reduce lead times, lower costs, and allow for greater design freedom compared to conventional subtractive methods.
[0003] Despite these advantages, conventional additive manufacturing techniques still face multiple challenges. Among these are concerns related to the dimensional accuracy, surface quality, and internal stress development in built parts. These issues often necessitate extensive post-processing operations, which can offset the time and cost benefits associated with additive manufacturing. Moreover, the lack of integrated control over process variations can result in inconsistent product quality, making it less suitable for applications requiring high mechanical reliability and surface precision.
[0004] These limitations have driven continued research and development toward advanced manufacturing systems that can offer enhanced process control, better material properties, and reduced dependence on secondary finishing methods. Addressing such challenges is essential for realizing the full potential of additive manufacturing in critical and high-performance applications.

SUMMARY OF THE INVENTION
[0005] In view of the foregoing disadvantages inherent in the prior art, the general purpose of the present disclosure is to provide a hybrid wire arc additive manufacturing (WAAM) system and method therof, to include all advantages of the prior art, and to overcome the drawbacks inherent in the prior art.
[0006] Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
[0007] An object of the present disclosure is to ameliorate one or more problems of the prior art or to at least provide a useful alternative. An object of the present disclosure is to provide a hybrid wire arc additive manufacturing (WAAM) system.
[0008] Another object of the present disclosure is to provide a method for hybrid manufacturing of metallic components using a wire arc additive manufacturing system.
[0009] Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
[0010] The present invention relates to a hybrid wire arc additive manufacturing (WAAM) system that integrates an in-line burnishing tool to improve the surface quality and mechanical properties of metallic components during fabrication. The system features a robotic manipulator equipped with a WAAM torch that performs directed energy deposition by melting a continuous wire feedstock using an electric arc. This setup enables precise layer-by-layer construction of metal parts with complex geometries. What distinguishes this system is the incorporation of a burnishing tool mounted immediately adjacent to the WAAM torch on the same robotic arm, allowing the deposited surface to be mechanically enhanced in real-time without interrupting the build process.
[0011] The burnishing tool is specifically designed to plastically deform the surface of the newly deposited layers, effectively reducing surface roughness and mitigating tensile residual stresses that are typically generated during additive manufacturing. By applying controlled compressive forces to the material, the burnishing tool improves surface finish and helps prevent defects such as warping or cracking that arise from residual stresses. The tool often takes the form of a spherical ball burnisher made of hardened material, enabling consistent and effective surface treatment throughout the build.
[0012] To ensure coordinated operation between deposition and surface enhancement, the robotic manipulator is controlled by a multi-axis controller that can alternate or combine the additive manufacturing and burnishing steps. This arrangement allows the burnishing tool to follow closely behind the WAAM torch, performing mechanical surface treatment immediately after or even during the cooling phase of each deposited layer. Such synchronization eliminates the need for secondary surface finishing operations, streamlining the manufacturing workflow and reducing production time.
[0013] Further, the system includes a sensor unit that monitors various process parameters in real time. These sensors may include infrared temperature sensors, laser profilometers for layer height measurement, acoustic emission sensors to detect material behavior, and high-resolution vision cameras for surface inspection. By capturing critical data such as temperature, deposition geometry, surface roughness, and residual stress levels, the system gains comprehensive insight into the quality of each deposited layer as it is formed.
[0014] This real-time sensor data is fed into a feedback control module that dynamically adjusts the process parameters to optimize both deposition and burnishing. For instance, if sensors detect excessive tensile residual stress in a specific area, the control system can increase the burnishing force or dwell time locally to introduce beneficial compressive stresses, thereby enhancing fatigue resistance and dimensional stability. Similarly, deposition parameters like torch travel speed and wire feed rate can be modified on the fly to ensure consistent bead geometry and material bonding.
[0015] The feedback control operates as a closed-loop system, continuously synchronizing the speeds and paths of the WAAM torch and burnishing tool to maintain precise coordination during the build. This closed-loop approach enables adaptive manufacturing where process adjustments are made layer-by-layer, preventing defect accumulation and improving overall part quality. Moreover, this integration reduces the reliance on expensive and time-consuming post-processing steps such as machining or grinding, leading to cost and time savings.
[0016] Further enhancing the system’s capabilities, process data from each layer can be stored and utilized by machine learning algorithms to predict optimal deposition and burnishing parameters for future builds. This predictive capability allows the manufacturing process to self-optimize over time, improving repeatability and reducing variability between parts even when fabricating different geometries or using varying materials.
[0017] The burnishing tool is designed to be retrofit-compatible and detachable, making it easy to integrate into existing WAAM robotic systems without extensive modifications. This flexibility ensures that manufacturers can upgrade their additive manufacturing setups to include the hybrid burnishing functionality without significant capital investment or downtime.
[0018] In an aspect of the present disclosure a method for hybrid manufacturing of metallic components using a wire arc additive manufacturing system involves depositing metallic material using the WAAM torch, followed by sensing key process parameters either during or immediately after each layer’s deposition. Using the burnishing tool mounted adjacent to the WAAM torch, a mechanical surface enhancement operation is applied to the newly deposited layer. The burnishing force and parameters are dynamically adjusted based on sensor feedback, ensuring optimal surface quality and stress management throughout the build process.
[0019] Residual stresses detected by the sensor unit can be specifically targeted by modifying the burnishing force or dwell time, enabling progressive stress relief layer-by-layer. This continuous approach helps manage inter-layer stress accumulation, preventing warping and cracking. Moreover, the angular offset positioning of the WAAM torch and burnishing tool facilitates simultaneous or sequential operation without requiring time-consuming tool changeovers.
[0020] In addition to real-time adjustments, the method includes storing detailed process data from each layer. This data can be leveraged by machine learning algorithms to predict and optimize burnishing and deposition parameters for future builds, increasing process robustness and part quality over time. Such intelligent control enables the system to self-learn and continuously improve manufacturing outcomes.
[0021] The burnishing tool’s retrofit-compatible and detachable design allows easy integration with existing WAAM robotic systems, providing manufacturers with a cost-effective upgrade path to add hybrid manufacturing capabilities.

BRIEF DESCRIPTION OF DRAWING
[0022] The foregoing summary, as well as the following detailed description of various embodiments, is better understood when read in conjunction with the drawings provided herein. For the purposes of illustration, there are shown in the drawings exemplary embodiments; however, the presently disclosed subject matter is not limited to the specific methods and instrumentalities disclosed.
[0023] Figure 1 illustrates a schematic diagram of a hybrid wire arc additive manufacturing (WAAM) system; and
[0024] Figure 2 illustrates a schematic diagram of different components of the hybrid wire arc additive manufacturing (WAAM) system as disclosed in the present disclosure;
[0025] Figure 3 illustrates a schematic layout of the integrated WAAM (Wire Arc Additive Manufacturing) system, showcasing its major mechanical and electronic components;
[0026] Figure 4
[0027] Like reference numerals refer to like parts throughout the description of several views of the drawing.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well- known apparatus structures, and well-known techniques are not described in detail.
[0029] The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a," "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," "including," and "having," are open-ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
[0030] The following detailed description should be read with reference to the drawings, in which similar elements in different drawings are identified with the same reference numbers. The drawings, which are not necessarily to scale, depict illustrative embodiments and are not intended to limit the scope of the disclosure.
[0031] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed. In this application, the use of the singular includes the plural, the word "a" or "an" means "at least one", and the use of "or" means "and/or", unless specifically stated otherwise. Furthermore, the use of the term "including", as well as other forms, such as "includes" and "included", is not limiting. Also, terms such as "element" or "component" encompass both elements and components comprising one unit and elements or components that comprise more than one unit unless specifically stated otherwise.
[0032] Furthermore, the term “module”, as used herein, refers to logic embodied in hardware or firmware, or to a collection of software instructions, written in a programming language, such as, Java, C, C++, python, or assembly. One or more software instructions in the modules can be embedded in firmware, such as in an EPROM. The modules described herein can be implemented as either software and/or hardware modules and can be stored in any type of non-transitory computer-readable medium or other storage device. Some non-limiting examples of non-transitory computer-readable media include CDs, DVDs, BLU-RAY, flash memory, and hard disk drives.
[0033] As illustrated in Figure 1 and 2, the system as disclosed in the present disclosure comprises a robotic manipulator (100) integrated with a wire arc additive manufacturing (WAAM) torch (105). The entire configuration is designed to perform directed energy deposition (DED) for the fabrication and enhancement of metallic components. The robotic manipulator (100) is a programmable, multi-degree-of-freedom mechanical system capable of precise and repeatable movements across multiple axes. It serves as a motion platform that facilitates the spatial manipulation of the WAAM torch (105) during the additive manufacturing process. The manipulator (100) allows for the deposition head, i.e., the WAAM torch (105), to be accurately positioned and oriented in three-dimensional space with respect to the workpiece or build substrate. This provides the necessary flexibility to fabricate parts with complex geometries and varying surface orientations. The manipulator (100) may include rotary and prismatic joints, driven by electric servo motors or hydraulic actuators, and is controlled through an embedded control unit or external programmable logic controller (PLC) or computer numerical control (CNC) system, allowing dynamic path planning and real-time adjustment of deposition trajectories.
[0034] The WAAM torch (105) is mounted on a distal end of the robotic manipulator (100), acts as the core additive deposition unit. The torch (105) functions analogously to a traditional arc welding torch (105) but is uniquely configured for additive manufacturing applications. In particular, the WAAM torch (105) is capable of feeding a continuous metallic wire into a high-energy electric arc generated between the torch (105)’s electrode and the workpiece or previously deposited layers. The arc serves as the heat source to melt the wire, while the manipulator (100)'s motion facilitates precise control over the deposition path. The torch (105) assembly includes critical components such as a wire feeder mechanism, a contact tip for current transfer, a shielding gas nozzle, and often a cooling system to maintain thermal stability during extended operation. The wire feed rate, arc current, travel speed, and gas flow rate are parameters carefully controlled to ensure consistent bead geometry and strong metallurgical bonding between successive layers.
[0035] The WAAM torch (105) is configured specifically to perform directed energy deposition (DED), a subclass of additive manufacturing techniques characterized by the focused application of thermal energy to simultaneously melt and deposit feedstock material at the point of interaction. Unlike powder-based DED systems, the WAAM system utilizes a solid wire as feedstock, which is advantageous in terms of material efficiency, lower health risks, and ease of handling. During operation, the wire is directed into the heat-affected zone (HAZ) created by the arc, where it rapidly melts and deposits onto the substrate. As the robotic manipulator (100) moves the torch (105) along a predetermined toolpath, the molten material solidifies upon cooling, thereby incrementally building up the desired component in a layer-by-layer fashion. The combination of the WAAM torch (105) and robotic manipulator (100) ensures high deposition rates and the ability to fabricate large-scale metallic structures with reduced dependency on post-processing.
[0036] In an embodiment of the present disclosure, a burnishing tool (110) is mounted adjacent to the WAAM (Wire Arc Additive Manufacturing) torch (105), creating a unified hybrid tool head capable of performing both additive deposition and mechanical surface enhancement in a synchronized or sequential manner. The burnishing tool (110) is a mechanical device designed to plastically deform the surface of the newly deposited metallic layer without removing material, by applying controlled force through a hard, smooth, typically spherical tip often made of hardened steel, tungsten carbide, or ceramic. This contact induces localized compressive stresses on the surface, which significantly improves the surface integrity and quality of the deposited component. By placing the burnishing tool (110) immediately adjacent to the WAAM torch (105), the invention ensures that burnishing can occur in close temporal and spatial proximity to the deposition process either immediately after or even during the solidification phase of each layer without requiring repositioning, manual intervention, or tool changeover.
[0037] The primary purpose of the burnishing operation is to reduce surface roughness and alleviate tensile residual stresses that are inherently introduced during high-heat deposition processes such as WAAM. As each molten layer solidifies and contracts, it can generate tensile residual stresses within the material, which, if left unmanaged, may cause warping, cracking, or even premature failure of the component under service conditions. Moreover, WAAM surfaces, due to the nature of molten metal flow and solidification dynamics, often exhibit high surface roughness with visible ripples or undulations between adjacent beads. These surface irregularities not only require extensive post-processing by machining or grinding but can also negatively affect fatigue life and dimensional tolerance. The integrated burnishing tool (110) mitigates these issues by smoothing the surface through plastic deformation and inducing beneficial compressive stresses that counteract the undesirable tensile stresses.
[0038] The proximity of the burnishing tool (110) to the WAAM torch (105) is critical for real-time, in-line processing. The invention ensures that as the torch (105) moves along the deposition path, the burnishing tool (110) trails closely behind, engaging with the recently deposited and cooled material typically while it is still warm and thus more ductile to perform the surface treatment operation effectively. This positioning enables the system to apply compressive force layer by layer, resulting in a cumulative improvement in part geometry and stress distribution as the build progresses. The adjacent mounting also eliminates the need for secondary fixturing or external surface treatment equipment, thereby streamlining the manufacturing process and reducing production time and cost.
[0039] The motion and synchronization of the torch (105) and burnishing tool (110) are managed by an electronic control unit. The control unit utilizes an Arduino Mega microcontroller interfaced with a RAMPS 1.4 shield to drive multiple stepper motors that control movement along the X, Y, Z, and feeder axes. Limit switches are employed for accurate homing and movement constraints. The motion system enables precise coordination between deposition and burnishing, ensuring that the burnishing tool (110) follows the torch (105) with an appropriate lag to treat each newly deposited layer effectively.
[0040] In another embodiment of the present disclosure, a sensor unit is integrated into the system for real-time monitoring and control. The sensor unit include infrared sensors for temperature profiling, laser profilometers for assessing deposition height and layer consistency, and vision-based systems for surface inspection. The feedback from these sensors allows the control unit to dynamically adjust process parameters such as torch (105) current, wire feed rate, burnishing force, and travel speed. This adaptive control mechanism enables intelligent manufacturing, ensuring consistent part quality despite variations in ambient or material conditions.
[0041] Moreover, the present system comprises a feedback control module integrates real-time sensor data with control protocols to orchestrate precise coordination between the additive and surface enhancement processes. This module is operatively linked to both the sensor unit and the robotic controller, forming a closed-loop control system that continuously monitors and regulates the system’s performance to ensure optimal manufacturing outcomes. The sensor unit, which may include thermal cameras, laser profilometers, vision systems, and acoustic emission sensors, captures a comprehensive range of process parameters such as layer height, deposition temperature, surface roughness, and residual stress. These raw signals are interpreted by the feedback control module, which applies predefined logic, adaptive thresholds, or machine learning algorithms to determine whether the current process state deviates from ideal conditions.
[0042] Once an anomaly or deviation is detected for example, if excessive surface roughness or high residual tensile stress is observed the control module instantly sends corrective commands to the robotic controller. This allows dynamic adjustment of either the burnishing parameters (e.g., force, dwell time, speed, and path overlap) or the WAAM deposition path (e.g., torch (105) angle, travel speed, current, or voltage) in real-time. For instance, if the sensor detects that the material has not been sufficiently plastically deformed to induce compressive stress, the control module can increase the normal force of the burnishing tool (110) or slow down its traverse speed to allow for a more effective mechanical treatment. Similarly, if the thermal gradient across a layer indicates a risk of warping or uneven cooling, the deposition strategy can be altered adjusting the inter-layer delay time or modifying the bead orientation to mitigate these risks.
[0043] This responsive control architecture plays a pivotal role in minimizing defects, improving interlayer bonding, and enhancing the surface finish progressively during the build process, rather than relying on expensive and time-consuming post-processing methods after fabrication is complete. Furthermore, the closed-loop system allows each new layer to benefit from corrective measures based on the performance of the previous ones, creating a self-optimizing environment. This not only improves part quality but also significantly reduces variability between builds, which is critical in high-precision industries such as aerospace, defense, and medical device manufacturing. Additionally, the integration of feedback loops ensures repeatability and reliability in long-duration builds, where thermal stresses and geometric deviations often accumulate over time.
[0044] The intelligent feedback module may also include learning-based algorithms that evolve over time by analyzing historical process data, identifying patterns, and refining control strategies for similar geometries or materials. This transforms the WAAM system from a deterministic, static machine into a smart, adaptive platform capable of tailoring its operations to different shapes, stress profiles, and tolerance requirements. By embedding intelligence into the manufacturing process, the invention achieves greater autonomy, fewer manual interventions, and superior component quality ultimately fulfilling the goal of high-efficiency, low-waste, low-cost additive manufacturing with minimal post-processing.
[0045] In an example implementation, as illustrated in the figure 3, the system is housed in a robust structural frame (301), which provides mechanical stability and ensures vibration-free operation during the deposition and burnishing processes. The Y-axis (302) and X-axis (303) each offer 300 mm of travel, while the Z-axis (304) allows for 200 mm of vertical movement, enabling 3D maneuverability of the WAAM torch and associated tools. Mounted on top is a precision spindle assembly (306) rated at 2.5 kW, capable of accommodating various end-effectors, including the WAAM torch and in-line burnishing tools. The T-slot table (305) acts as the primary workspace where substrates or build plates are mounted, and it is designed to handle dynamic loads and thermal stresses during multi-layer deposition.
[0046] Importantly, the setup includes an intrade build plate (309) serves as the deposition platform. This build plate is supported by a tilt plate (308) that allows the welding torch to tilt within a range of ±15 degrees, enabling the system to fabricate components with complex geometries or sloped surfaces without needing additional fixtures. The tilt mechanism adds significant flexibility and accuracy in torch orientation, enhancing bead uniformity and fusion quality. The system is controlled via a dedicated PC interface (307), which serves as the operational command center for both the robotic control software and the feedback control module. Overall, this figure encapsulates the hardware configuration necessary for executing intelligent, high-efficiency hybrid WAAM processes with real-time adjustments, supporting both additive and surface finishing operations within a compact and user-friendly setup.
[0047] In an aspect of the present disclosure the present invention provides a hybrid manufacturing method for producing metallic components by integrating wire arc additive manufacturing (WAAM) with an in-line burnishing process. In this method, a robotic manipulator (100) equipped with a WAAM torch (105) deposits metallic material layer by layer to build the component. Each layer is created by melting and depositing wire feedstock using the electric arc generated by the WAAM torch (105), which follows a predetermined tool path to achieve the desired geometry.
[0048] During or immediately after the deposition of each layer, the system uses a sensor unit mounted near the WAAM torch (105) to monitor critical process parameters. These parameters can include, but are not limited to, temperature, layer geometry, surface roughness, and notably, residual stresses within the newly deposited layer. The sensing step provides real-time data that is essential for maintaining process control and ensuring the quality of each layer.
[0049] Following the deposition and sensing, the method employs a mechanical surface enhancement operation through a burnishing tool (110) mounted adjacent to the WAAM torch (105) on the same robotic end-effector. This burnishing tool (110) applies controlled mechanical pressure on the surface of the freshly deposited layer to plastically deform surface asperities, thereby improving surface finish and reducing surface roughness. Additionally, the burnishing process induces compressive residual stresses in the material, which are beneficial for enhancing fatigue resistance and minimizing distortion.
[0050] Further, the method includes dynamic adjustment of burnishing parameters and tool paths in real time, based on the sensor data collected during or after each layer’s deposition. A feedback control module processes the sensed information and modifies parameters such as burnishing force, dwell time, and tool trajectory to optimize surface quality and stress profiles progressively throughout the build. For example, if residual stress measurements indicate excessive tensile stress in certain regions, the burnishing force or dwell time can be increased locally to counteract and reduce such stresses effectively.
[0051] The burnishing operation is typically applied after the deposition of each layer, allowing for progressive management of inter-layer stress accumulation and maintaining a high-quality surface throughout the additive manufacturing process. The WAAM torch (105) and burnishing tool (110) are arranged with an angular offset on the same end-effector, enabling either simultaneous or sequential operation without the need for tool changeover, thus improving overall manufacturing efficiency.
[0052] Furthermore, the method includes storing detailed process data for each layer, which can be utilized by machine learning algorithms to predict and optimize future deposition and burnishing parameters. This predictive capability enables continuous improvement and adaptation of the process for enhanced quality and reduced post-processing requirements. The burnishing tool (110) is also designed to be retrofit-compatible and detachable, allowing easy integration with existing WAAM robotic systems without extensive modifications.
[0053] While considerable emphasis has been placed herein on the specific features of the preferred embodiment, it will be appreciated that many additional features can be added and that many changes can be made in the preferred embodiment without departing from the principles of the disclosure. These and other changes in the preferred embodiment of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.
[0054] While the invention has been described in connection with what is presently considered to be the most practical and various embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements.
[0055] The embodiments described above are intended only to illustrate and teach one or more ways of practicing or implementing the present invention, not to restrict its breadth or scope. The actual scope of the invention, which embraces all ways of practicing or implementing the teachings of the invention, is defined only by the following claims and their equivalents.
, Claims:We Claim:
1. A hybrid wire arc additive manufacturing (WAAM) system with integrated in-line burnishing, comprising:
a robotic manipulator (100) comprising a wire arc additive manufacturing (WAAM) torch (105) configured to perform directed energy deposition;
a burnishing tool (110) mounted adjacent to the WAAM torch (105), to deform the deposited surface to reduce surface roughness and tensile residual stress;
a multi-axis robotic arm controller configured to alternate or combine additive manufacturing and burnishing operations during or after each layer deposition;
a sensor unit to monitor a plurality of parameters including temperature, residual stress, surface roughness, and deposition height in real time; and
a feedback control module operatively connected to the sensor unit and robotic controller, configured to dynamically adjust burnishing parameters and/or deposition path based on the monitored data to optimize part quality and reduce post-processing.

2. The system as claimed in claim 1, wherein the burnishing tool (110) is a spherical ball burnishing tool (110).

3. The system as claimed in claim 1, wherein the sensor unit includes one or more of, an infrared temperature sensor, laser profilometer, acoustic emission sensor, or high-resolution vision camera.

4. The system as claimed in claim 1, wherein the feedback control module comprises a closed-loop control protocol configured to synchronize burnishing and deposition speeds in real time.

5. A method for hybrid manufacturing of metallic components using a wire arc additive manufacturing system with in-line burnishing, the method comprising the steps of:
depositing a metallic material layer using a wire arc additive manufacturing torch (105) mounted on a robotic manipulator (100);
` sensing at least one process parameter during or after the deposition of each layer using a sensor unit;
applying a mechanical surface enhancement operation using a burnishing tool (110) mounted adjacent to the WAAM torch (105) on the same end-effector; and
dynamically adjusting burnishing parameters and/or tool paths in real time based on sensed data using a feedback control module to enhance surface finish, reduce residual stress, and minimize post-processing.

6. The method as claimed in claim 5, wherein sensing comprises measuring residual stresses and adjusting the burnishing force or dwell time accordingly.

7. The method as claimed in claim 5, wherein burnishing is applied after the deposition of each layer to progressively manage inter-layer stress accumulation.

8. The method as claimed in claim 5, wherein the WAAM torch (105) and burnishing tool (110) are positioned with an angular offset to enable simultaneous or sequential processing without tool changeover.

9. The method as claimed in claim 5, further comprising storing process data for each layer and using machine learning algorithms to predict and optimize future deposition-burnishing parameters.

10. The method as claimed in claim 5, wherein the burnishing tool (110) is retrofit-compatible and detachable from the robotic end-effector.