BTW | WHAT IS WAAM?
For the past few decades, research has been assessing the implications of Additive Manufacturing (AM, or
3D-printing) across many industries. AM is a technology that promises to reduce part cost by reducing
material wastage and time to market. Furthermore, AM can also enable an increase in design freedom, which
potentially results in weight-saving as well as facilitating the manufacture of complex assemblies formerly
made of many subcomponents.
Especially, the potential of printing metals is of high interest to researchers and scientists around the
globe. More recently, we have seen the successful application of a technology coined Wire Arc Additive
Manufacturing – or WAAM in short. It allows for high volume output, great scalability, and very good
mechanical performance. For prototypes and small-batch production runs, in particular, WAAM is a more
cost-effective solution than other additive or subtractive manufacturing processes for metal.
The WAAM process starts with a 3D CAD file, which is processed by software running algorithms in which the
3D model is sliced in many layers. Wire Arc Additive Manufacturing (WAAM) uses arc welding technology to
build up a component in layers, this means a metal wire is melted at the right place using a MIG welding
torch to form the desired blank. WAAM hardware currently uses standard, off the shelf and low-cost welding
equipment: welding power source, torches, and wire feeding systems. Motion can be provided either by robotic
systems or computer numerical controlled gantries, for which the path is automatically generated at the
click of a button.
A variety of materials, such as common mild steel, stainless steel, aluminium, titanium, and nickel-based
metals are perfectly suitable for this AM process. As of today, countless components have already been
produced using WAAM technology in a variety of sectors: impellers for machines, airplane parts for the
aviation industry, car-body prototypes for automotive, and even an entire bridge for the Arts and AEC
sector. Apart from building components purely additively, post-production steps such as polishing and/or
machining are possible to fabricate hybrid components that feature both rapid manufacturing and very high
precision. It is even possible to repair components using WAAM technology.
The Future of Manufacturing
With support from the Innovative Manufacturing Cooperative Research Centre (IMCRC), Design Robotics is collaborating to present a range of new
fabrication and vision systems solutions. The goal is simple – to design for human intelligence and optimize
the relationship between people and machines.
Pushing the limits of industrial robotics is a move to empower people. Navigating the increasing complexity
of manufacturing inevitably supports human experience and enhances skills acquisition. At its heart, this
approach celebrates the best of what robots and machines can achieve – problem-solving, and the best of what
humans can do – social intelligence and contextual understanding. The remaining question is, what would you
manufacture today, tomorrow, and in the future using WAAM?
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