This paper presents the development and industrial deployment of a Digital Twin-enabled hybrid manufacturing cell to produce large-scale components, providing end-to-end digital continuity from initial design through to final dimensional verification [1]. The study demonstrates that Digital Twin architecture can effectively support the industrialization of hybrid manufacturing cells, integrating additive and subtractive manufacturing, in-process monitoring, and advanced coating operations into a unified, data-driven workflow. This approach ensures accurate dimensional control, consistent part quality, and full traceability, offering a robust framework for the fabrication of large-scale components with complex geometries. The workflow begins with the creation of a digital twin of the robotic cell and its associated tools, facilitating the redesign of components to accommodate robot kinematics and accessibility constraints. Subsequently, the DED-WAAM deposition process is then simulated using Finite Element Method to predict thermal gradients, residual stresses, and potential geometric distortions. The results of this simulation inform the programming of robot toolpaths and process parameters, ensuring precise layer-by-layer deposition and enabling the part to achieve its near-net-shape geometry with minimal post-processing. A full-scale demonstrator mold was fabricated using the DED-WAAM process, fully integrated within a multi-functional robotic cell consisting of a six-axis industrial robot, a dual-axis rotating positioner, and multiple interchangeable end-effectors [2, 3]. 3D scanning was operated to verify dimensional conformity and to generate the corresponding machining program. The workflow incorporates both rough and smooth machining executed by the robot, in coordination with the positioner, with intermediate 3D scans after each stage to ensure dimensional accuracy and to compensate for geometric deviations. In-process monitoring is achieved through multiple sensors capturing key parameters of the DED-WAAM deposition, machining, and robotic kinematics at different acquisition frequencies. Non-destructive dimensional verification is conducted using the MEPULS ultrasonic sensor, developed by VLB Systemes, providing the part thickness feedback to maintain geometric fidelity throughout the machining process.

Finally, the workflow integrates a Cold Spray deposition of Nb-based superalloy onto the final net-shape mold, producing a high-performance aerospace part capable of withstanding extreme thermal conditions. All process data from FE simulations, WAAM and machining parameters, to ultrasonic measurements, and 3D scan results are systematically captured and managed within the digital continuity framework, ensuring complete traceability, reproducibility, and process consistency across the entire manufacturing chain.

Keywords
WAAM, Robotic Machining, Industry 4.0, Monitoring, Dimensional Control, 3D Scanning, Traceability

References
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a Robotic Additive Manufacturing Cell Using Wire-Based Laser Metal Deposition, Processes
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Technologies – An Analysis Regarding Potentials and Applications, Physics Procedia 83
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