Induction heating (IH), a clean energy source, is potentially used to develop wire additive manufacturing (AM) system. The optimised parameters that simultaneously melt the mild steel wire and raise the substrate temperature is established. A fully coupled thermal-electromagnetic model of AM system is developed to perform numerical experiments on temperature development. The proposed hybrid helical-pancake coil with circular cross-section melt the metallic wire and raise the substrate temperature to 1490 K. The hybrid coil provides rapid heating to the wire (2819 K) and substrate together by enhancing magnetic field strength. The experiments using high-frequency IH system (550 A and 353 kHz) with a 3-turn helical coil is validated with model results for 2 mm mild steel wire.
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