Strengthening of Metal Thin Plates Through Wire-Arc Additive Manufacturing

Wire-Arc Additive Manufacturing (WAAM) is a metal 3D printing technology suitable to realize medium- to large-scale steel components suitable for applications in Architecture, Engineering and Construction (AEC) sectors. Given the high flexibility of this advanced technology, the additive fabrication of metal parts with almost no geometrical constraints can be adopted either to create new complex-shaped steel elements or to strengthen existing ones. This work proposes a novel approach for the structural strengthening of thin metal plates through WAAM. The study explores the conceptual design, numerical optimization, and fabrication of ribbed stiffening patterns directly deposited onto thin steel substrates. Leveraging the design freedom of WAAM, various rib topologies were parametrically defined and optimized to enhance local stiffness, buckling resistance, and overall load-bearing efficiency while minimizing material use. The optimized configurations were validated through finite element simulations and subsequently fabricated to assess geometric accuracy, material integrity, and adhesion behavior between the substrate and the deposited ribs. Preliminary experimental tests confirmed a significant improvement in mechanical performance compared to flat reference plates, demonstrating the potential of WAAM in structural and industrial applications, offering a pathway to lightweight and tailored metal structures.