A hybrid thermal-geometrical model in analytic, distributed-parameter dynamic for is established for thermal material deposition in solid freeform fabrication processes. It consists of a temperature field description by convolution of step distribution responses, with in-process identification of the thermal efficiency through temperature measurements. This is coupled to a geometric formulation based on superposition of elementary deposition distributions, approximated by simple ellipsoidal primitives. The shape parameters are thermally constrained and adjusted in real time by geometric profile data. The combined model is tested in robotic PAW-based material deposition by wire feeding, with feedback by infrared pyrometry and laser profilometry, and intended for geometry control in thermal rapid prototyping.
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