Advancing nuclear manufacturing through Wire Arc Additive Manufacturing (WAAM)
Framatome, a global leader in nuclear power technology, sought to explore the feasibility of Wire Arc Additive Manufacturing (WAAM) for producing large, safety-critical components. The company selected a full-scale stainless steel impeller as a benchmark case to test WAAM’s capacity for dimensional precision, mechanical integrity, and repeatability.
Conventional manufacturing of such an impeller involves long lead times, heavy material waste, and high tooling costs. Framatome aimed to assess whether WAAM could provide a faster, more flexible alternative while maintaining the strict standards required by the nuclear industry.
Solution
MX3D collaborated with Framatome’s R&D team to manufacture the impeller using its robotic WAAM technology. The project was structured in three development stages:
- Design and print strategy development, including digital path optimization and simulation.
- Partial prototype fabrication to validate deposition parameters, cooling control, and structural consistency.
- Full-scale impeller production, combining precision printing, heat treatment, and finishing.
To accommodate the impeller’s total weight of approximately 1.4 to 1.5 tons, MX3D equipped its MX Metal AM Machine with a high-payload 2-axis manipulator, enabling controlled rotation and accessibility during printing.
Process
The impeller was printed in 316L stainless steel using MX3D’s WAAM system. e. Dimensional accuracy was verified through 3D scanning at each key stage, both as-printed and post-machining, ensuring complete traceability of the process.
The final geometry was achieved through CNC milling, confirming the dimensional fidelity and surface quality of the printed impeller. All stages were monitored and logged using MX3D’s MetalXL software, providing a digital record of deposition parameters, temperature data, and process control.
Result
The collaboration between Framatome and MX3D successfully demonstrated that WAAM is a viable manufacturing method for large, complex components in the nuclear sector. The impeller prototype met all project objectives, showing excellent material quality, dimensional stability, and repeatability across the build.
This achievement highlights WAAM’s potential to reduce lead time, material waste, and cost compared to conventional fabrication routes, while maintaining full traceability and compliance with industrial standards. The project also achieved a significant reduction in the manufacturing CO2 footprint.
For Framatome, the project represents a major step forward in integrating advanced additive technologies into nuclear manufacturing. For MX3D, it confirms WAAM’s strength in producing high-value, mission-critical components for one of the world’s most demanding industries.
Project Data
- Client: Framatome
- Part: Full-scale impeller prototype
- Technology: Wire Arc Additive Manufacturing (WAAM)
