Learning and Adaptation in Wire Arc Additive Manufacturing Bead Geometry Control

Real-time weld-pool perception is critical for closed-loop control in laser wire-feed welding, where sensing, computation, and actuator response introduce unavoidable delay. This paper presents a physics-guided spatiotemporal state space network for lookahead weld-pool segmentation. The model uses historical coaxial grayscale images, welding process parameters, and aligned wire-state electrical signals to predict the future semantic layout of three physically meaningful regions: keyhole, wire, and molten pool. It combines a visual encoder, process- and sensor-conditioned feature normalization, patch-level temporal state space modeling, horizon-conditioned latent prediction, dense future feature prediction, and a motion-aware mask decoder. Auxiliary signed-distance-function supervision, temporal consistency, feature distillation, and fine-grained keyhole losses further constrain the predicted geometry and local motion. Experiments on a 43-sequence laser welding dataset show that the proposed WeldMamba reaches 74.63% mIoU at a 500 ms lookahead. Ablation studies further show that temporal history, patch-level state space modeling, and keyhole motion awareness are the main contributors to robust future segmentation.

World Action Models (WAMs) have emerged as a promising paradigm for robot control by modeling physical dynamics. Current WAMs generally follow two paradigms: the "Imagine-then-Execute" approach, which uses video prediction to infer actions via inverse dynamics, and the "Joint Modeling" approach, which jointly models actions and video representations. Based on systematic experiments, we observe a fundamental trade-off between these paradigms: the former explicitly leverages world models for generalizable transit but lacks interaction precision, whereas the latter enables fine-grained, temporally coherent action generation but is constrained by the exploration space of the training distribution. Motivated by these findings, we propose HarmoWAM, an end-to-end WAM that fully leverages a world model to unify predictive and reactive control, enabling both generalizable transit and precise manipulation. Specifically, the world model provides spatio-temporal physical priors that condition two complementary action experts: a predictive expert that leverages latent dynamics for iterative action generation, and a reactive expert that directly infers actions from predicted visual evolution. To enable adaptive coordination, a Process-Adaptive Gating Mechanism is proposed to automatically determine the timing and location of switching between them. This allows the world model to drive the reactive expert to expand the exploration space and the predictive expert to perform precise interactions across different stages of a task. For evaluation, we construct three training-unseen test environments across six real-world robotic tasks, covering variations in background, position, and object semantics. Notably, HarmoWAM achieves strong zero-shot generalization across these scenarios, significantly outperforming prior state-of-the-art VLA models and WAMs by margins of 33% and 29%, respectively.

Redundant robotic multi-axis additive manufacturing (MAAM) enables support-free and conformal fabrication, but trajectory optimization for long-horizon paths remains challenging under strict deposition-position constraints and time-varying collision constraints. This work proposes a computational framework for collision-aware trajectory optimization in redundant robotic MAAM. We first formulate nozzle-workpiece relative kinematics using a relative Jacobian, and develop a differentiable SDF-based collision model that captures fabrication-induced geometry evolution and provides optimization gradients. The deposition position is then enforced as a hard waypoint-wise equality constraint through iterative projection onto the self-motion manifold, with the loss gradient restricted to the corresponding tangent space. Experiments on an 8-DOF robotic MAAM platform with diverse long-horizon support-free and conformal toolpaths show that our method maintains a mean nozzle-position error below 10μm, reduces maximum joint jerk by up to $77.6\%$, and eliminates all sampled collision and orientation violations. Compared with the SQP-based baseline, it achieves up to a 10.2x speedup and improved convergence. Physical fabrication experiments further verify that the resulting smooth, collision-free trajectories enable successful printing of complex geometries with fewer visible deposition artifacts.