Lightweight design meets architectural freedom through Wire Arc Additive Manufacturing (WAAM)
In Zaandam, the Netherlands, an innovative residential project demonstrates how Wire Arc Additive Manufacturing (WAAM) can redefine what’s possible in architectural construction. The project centered around a custom veranda deck and top beam, designed to reduce structural weight while adding aesthetic character, a perfect showcase of how MX3D’s metal 3D printing technology enables both efficiency and creativity.
The project team faced a clear engineering challenge: the existing design of the top beam required significant weight reduction to meet load-bearing and design constraints. Traditional fabrication methods could not deliver the necessary balance between mechanical strength, lightweight performance, and visual appeal.
To solve this, the architects and engineers turned to WAAM, a technology capable of creating optimized geometries that minimize material usage while maintaining strength. By leveraging MX3D’s advanced robotic metal printing system, the team achieved a nearly 50% weight reduction compared to a conventionally manufactured equivalent.
The structural element was printed directly in Corten steel, chosen for its strength, durability, and natural weathering qualities. The material forms a distinctive protective oxide layer, giving the veranda a warm, rust-toned finish that requires no additional coating or treatment.
This approach eliminated extra finishing steps, reduced environmental impact, and highlighted one of WAAM’s unique advantages, combining structural integrity with material expressiveness. The result is both technically sound and visually striking, an architectural feature that performs as well as it looks.
The project was led by French architect Julie Fuchs, known for her focus on sustainable, long-lasting design, in collaboration with J. Felsch, an architect specializing in transforming monumental buildings. Their joint vision merged traditional architectural sensitivity with state-of-the-art digital fabrication, creating a design that feels both timeless and forward-looking.
The veranda deck demonstrates how advanced manufacturing can complement heritage architecture, introducing modern efficiency and design freedom without disrupting the building’s historical character.
A Lightweight, Sustainable, and Expressive Structure
- A 50% lighter structural component
- A unique visual identity that enhances the architectural concept
- Elimination of additional finishing processes
- Direct manufacturing in Corten steel
