Additive Manufacturing Services: End-to-End WAAM for Industrial Projects

Key notes:

• Complete Engineering Partnership: Provides a full-service, end-to-end collaboration from initial feasibility assessments and Design for WAAM (DfAM) through to certified production, post-processing, and final logistical delivery.

• Bypasses Sourcing Bottlenecks: Directly resolves 6-to-18-month foundry lead times, supply constraints, and geometric limitations of traditional casting or solid-block machining.

• Industrial Scalability: Operates out of Europe’s largest WAAM facility, housing 15 specialised robots capable of continuous 24/7 automated production.

• Certified Quality Framework: Fully compliant with DNV, ASME, and Lloyd’s Register requirements, backed by full material traceability records and rigorous Non-Destructive Testing (NDT).

• Extensive Material Portfolio: Qualified to print a wide array of industrial alloys including mild steels, high-strength steels, stainless steels, duplex, Inconel, bronze, copper, and Aluminium.

Additive manufacturing services from MX3D provide a comprehensive end-to-end production partnership. When a large-scale metal component is delayed by 6-to-18-month casting lead times, blocked by foundry supply constraints, or requires a complex geometry that custom tooling simply cannot achieve, you do not need to purchase a machine—you need a reliable production partner.

MX3D’s additive manufacturing services cover the entire engineering journey: from feasibility assessment and Design for WAAM (DfAM), through DNV-certified robotic production and precise post-processing, to final delivery complete with full quality documentation. This is not a basic print-on-demand platform for standard widgets; it is an extensive engineering collaboration designed specifically for complex, heavy industrial B2B projects.

Our End-to-End WAAM Service: What’s Included

Our service bureau operates to solve industrial supply chain bottlenecks systematically.

Step-by-Step Project Journey

Step	Service Stage	What MX3D Delivers
1	Engineering Consultation & Feasibility	WAAM feasibility assessment, design review, material selection, and cost-benefit analysis versus traditional casting/forging.
2	Design for WAAM (DfAM)	Part design optimisation for WAAM deposition, topology optimisation where applicable, and precise toolpath simulation.
3	Material Qualification	Material selection confirmation, test coupon production, and mechanical property verification per relevant international standards.
4	WAAM Production	Robotic arc deposition under proprietary MetalXL software control, real-time process monitoring, and interpass inspection.
5	Post-Processing	Stress relief/heat treatment, Hot Isostatic Pressing (HIP) if required, and surface finishing through our trusted partners.
6	Certification & NDT	Dimensional inspection (CMM), Ultrasonic Testing (UT), Radiographic Testing (RT), and Penetrant/Magnetic Testing (PT/MT) certified by DNV, ASME, and Lloyd’s Register.
7	Delivery	Certified material documentation package, full digital traceability records, and logistics management.

Additive Manufacturing Services vs. Print-on-Demand

Understanding our engagement models ensures the right level of engineering support for your project workflow:

• Print-on-Demand: You supply a finished, ready-to-print digital design, and MX3D produces and ships it. This transaction is best suited for standard geometries, repeat orders, parts with existing operational specifications, and fast turnaround timelines.

• Additive Manufacturing Services: MX3D engineers are deeply embedded in your project from the initial feasibility study all the way through to final certified delivery. This approach is mandatory for new designs requiring topological weight reduction, safety-critical certified applications (offshore, maritime, defence), highly complex geometries, and first-of-a-kind production runs.

Why Choose MX3D for Additive Manufacturing Services

Proven Production Capability at Scale

Operating as Europe’s largest WAAM production facility, MX3D houses 15 specialised robots capable of continuous 24/7 automated production. We have successfully delivered globally recognised heavy-format fabrications, including a massive 750 kg industrial valve body and a 350-kilogram nickel-aluminium-bronze Framatome impeller tailored for the demanding energy sector.

Certified Quality for Demanding Industries

To guarantee total compliance and operational safety, MX3D maintains rigorous quality assurance protocols:

• DNV Certification: Fully compliant production for heavy offshore and maritime applications.

• ASME Compliance: Verified structural integrity for pressure equipment and vessels.

• ISO 9001: Strict adherence to international quality management systems across all operations.

Industries We Serve

Energy & Oil and Gas

Delivering DNV and ASME-certified parts for high-stress environments. Our pressure vessels, valve bodies, and the specialized Framatome impeller highlight our ability to engineer robust components from advanced duplex and super duplex grades.

Maritime & Shipbuilding

Slashing vessel downtime through the on-demand production of components like bronze propellers, Aluminium cowl vents, and custom bulb keels, ensuring fleets stay operational with advanced, corrosion-resistant alloys.

Defense

Securing supply chain independence by rapidly producing critical spare parts and robust structural elements using advanced alloys and high-strength steels, shortening vulnerable logistics loops.

Automotive

Accelerating vehicle development by fabricating custom manufacturing tooling, massive prototype vehicle chassis configurations, and optimized rugged parts like the WAAM wheel bracket.

Architecture & Construction

Unlocking new geometric possibilities for structural engineers. The famous MX3D Bridge and the Takenaka steel connector demonstrate how WAAM fabricates custom steel nodes and complex architectural elements directly from digital coordinates.

Manufacturing & Tooling

Streamlining factory floors with custom parts. WAAM is highly ideal for producing structural robot arms, industrial moulds, and heavy-duty pulper screws using carbon and tool steels.

Art & Design

Transforming visionary concepts into reality with limitless geometric freedom. The Dragon Bench, the bespoke Schindler elevator cart, and the intricate Butterfly Screen prove the seamless blend of artistic design and structural integrity.

Materials Available Through Our WAAM Services

MX3D utilizes standard commercial welding wires, drastically lowering raw material costs while using familiar, certified metallurgy.

Alloy Series / Wire Grade	Material Class	Material Specifications & Primary Applications
2319 Series	Aluminium	EN ISO 18273: S Al 2319 (AlCu6MnZrTi) – Aerospace standard alloy featuring high strength characteristics at elevated temperatures. Commonly used for specialised aerospace structural frames and custom defence fixtures.
4018 Series	Aluminium	EN ISO 18273: S Al 4018 (AlSi7Mg) – Highly fluid during melting with an excellent silicon content to prevent print cracking. Typically used for intricate industrial tooling, customised pump sections, and casings.
4046 Series	Aluminium	EN ISO 18273: S Al 4046 (AlSi10Mg) – High-silicon alloy offering excellent fluidity during melting to prevent print cracking. Ideal for intricate industrial tooling, customised pump sections, and casings.
5183 Series	Aluminium	EN ISO 18273: S Al 5183 (AlMg4,5Mn0,7(A)) – Non-heat-treatable marine grade alloy with outstanding corrosion resistance and high structural integrity. Ideal for maritime structures, yacht components, pressure vessels, and chemical fluid equipment.
5356 Series	Aluminium	EN ISO 18273: S Al 5356 (AlMg5Cr(A)) – Standard non-heat-treatable alloy providing outstanding corrosion resistance and high marine structural integrity. Used for maritime structures, yacht components, pressure vessels, and chemical fluid equipment.
6063 Series	Aluminium	EN ISO 18273: S Al 6063 (AlMg0.7Si) – Architectural-grade alloy offering good mechanical strength, easy weldability, and excellent structural versatility. Well-suited for civil engineering, architecture connectors, and general structural applications.
ER70S-6	Mild Steel	EN ISO 14341-A: G 46 4 M G4Si1 – The most common general-purpose mild steel welding wire, featuring high silicon for excellent puddle fluidity.
ER80S-D2	Mild Steel	EN ISO 14341-A: G 50 7 M 21 4Mo – Molybdenum-alloyed wire for welding higher-strength sheet metals and low-alloy steels.
ER90S-G	High-Strength Steel	AWS A5.28 – EN ISO 16834-A: G 55 4 M21 Mn3Ni1Mo – High-strength low-alloy wire designed for steel structures, pipelines, and machinery requiring high yield strength and impact toughness.
ER100S-G	High-Strength Steel	AWS A5.28 – EN ISO 16834-A: G 62 4 M13 Mn3NiCrMo – Low-alloy wire optimized for high-yield strength applications like heavy industrial machinery and cranes.
ER110S-G	High-Strength Steel	AWS A5.28 – EN ISO 16834-A: G 69 4 M21 Mn3Ni1CrMo – Very high-strength wire used for safety-critical structural applications and military defence equipment.
ER120S-G	High-Strength Steel	AWS A5.28 – EN ISO 16834-A: G 89 4 M21 Mn4Ni2CrMo – Ultra-high-strength wire engineered for specialized, heavy-duty structural steel welding.
Maraging Steels	Specialty Steel	Carbon-free iron-nickel alloys known for possessing superior strength and toughness without losing material malleability.
Tool Steels Fe3 & Fe8	Specialty Steel	Hard, highly abrasion-resistant alloys primarily used for repairing or fabricating manufacturing dies, industrial moulds, and cutting tools.
CuAl8	Bronze & Copper	EN ISO 24373: S Cu 6100 – Aluminium bronze alloy featuring high mechanical strength and excellent resistance to seawater and localized acids.
CuAl8Ni6	Bronze & Copper	EN ISO 24373: S Cu 6328 – Nickel-alloyed aluminium bronze optimized for even higher strength and exceptional erosion/corrosion resistance.
CuNi 70/30	Bronze & Copper	Copper-nickel alloy highly resistant to severe seawater corrosion; industry standard in desalination plants and marine piping.
CuSi3	Bronze & Copper	EN ISO 24373: S Cu 6560 – Silicon bronze; flows easily during deposition, ideal for joining plain or galvanized sheet steel and artistic metalwork.
CuSn6	Bronze & Copper	EN ISO 24373: Cu 5180A – Phosphor bronze alloy offering good wear resistance and low friction coefficient, often used for surfacing.
308LSi	Stainless Steel	EN ISO 14343 – A: 19.9LSi – Standard alloy for welding 304/304L stainless; added silicon improves weld pool fluidity and final bead appearance.
316LSi	Stainless Steel	EN ISO 14343 – A: 19.12.3LSi – Molybdenum-bearing alloy for welding 316/316L stainless, offering superior pitting corrosion resistance.
Duplex 2209 & 2205	Stainless Steel	Mixed microstructures (austenite/ferrite) offering high structural strength and excellent resistance to stress corrosion cracking.
Superduplex 2594	Stainless Steel	Highly alloyed duplex stainless steel engineered for extreme offshore, chemical, and petrochemical environments.
Martensitic 410NiMo	Stainless Steel	Used primarily for welding cast alloys in the hydropower and turbine industries; requires post-weld thermal heat treatment.
Precipitation Hardening 17-4PH	Stainless Steel	Chromium-copper stainless steel capable of achieving immense strength and hardness levels through post-print heat treatment; common in aerospace.
Inconel 625	Nickel-Based Superalloy	Nickel-chromium-molybdenum alloy with outstanding corrosion resistance and high-temperature strength; standard in marine and nuclear sectors.
Inconel 718	Nickel-Based Superalloy	Precipitation-hardenable superalloy that retains exceptional strength and oxidation resistance at extreme temperature boundaries (e.g., aerospace jet engines).

Frequently Asked Questions

What additive manufacturing services does MX3D offer?

MX3D provides a comprehensive, end-to-end Wire Arc Additive Manufacturing (WAAM) service. This spans initial engineering consultation, Design for Additive Manufacturing (DfAM), material qualification testing, 24/7 robotic production, non-destructive testing (NDT), and the final delivery of fully certified components.

How is this different from MX3D’s print-on-demand service?

Print-on-demand is a streamlined transaction where you upload a finalized design for immediate robotic production and shipping. Additive manufacturing services involve deep engineering collaboration from project inception, ensuring complex, massive, or first-of-kind parts are strategically optimized, certified, and compliant with heavy industry regulations.

Can MX3D provide certified parts for offshore or subsea applications?

Absolutely. MX3D operates a fully DNV-certified production environment specifically designed to serve the offshore, maritime, and subsea sectors. We routinely fabricate heavy flanges, manifolds, and pressure vessels utilizing certified duplex and super duplex stainless steels that undergo rigorous third-party NDT inspections.

What is the minimum project size for MX3D’s WAAM services?

Additive manufacturing services are highly optimized for large, complex, and structural projects. While there isn’t a strict boundary, these services excel for massive components weighing hundreds or thousands of kilograms, one-off specialized industrial equipment, or components requiring extensive engineering redesign and official civil or maritime certifications.

How long does a full-service WAAM project typically take from brief to delivery?

While traditional casting and open die forging for heavy components demand 6 to 18 months, MX3D’s end-to-end WAAM services vastly accelerate this timeline. Depending on the engineering complexity, material testing requirements, and the specific industrial components, a project can successfully transition from initial feasibility brief to certified delivery in a matter of weeks.

Ready to Use WAAM for Your Applications and Projects?

MX3D has produced heavy, certified WAAM components for demanding clients globally across offshore, maritime, defence, and architecture. Leverage our Amsterdam-based, DNV-certified production facility to bring your massive projects to life.

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