This study proposes a hybrid wire arc directed energy deposition (WA-DED) process that uses 3D sand-printed supports to overcome the limitations of low-angle overhang fabrication. WA-DED is a metal additive manufacturing process offering high deposition rates, cost efficiency, and suitability for large-scale components. However, because of its high heat input and molten pool instability, low-angle overhang and hollow structures remain difficult to fabricate, as the molten metal tends to collapse under gravity and thereby degrade geometric accuracy and surface quality. To address this issue, sand-printed supports were introduced. The supports provide tailored mechanical constraint and guide the solidification of the molten pool during deposition. Experiments were conducted to evaluate the feasibility of the proposed process at various overhang angles. The results show that the hybrid process markedly improves deposition stability and enables the fabrication of low-angle and curved overhang structures that conventional WA-DED cannot produce. These findings confirm the effectiveness of sand-supported WA-DED and highlight its potential for industrial applications requiring complex geometries, such as aerospace, marine, and energy components.
