Wire Arc Additive Manufacturing

WAAM System

The technology of Robotic Wire Arc Additive Manufacturing (WAAM) is essentially a welding robot programmed such that it deposits metal material layer-by-layer repeatedly to create specific metal applications.

Robotics

Robotic WAAM builds parts layer-by-layer by melting and dispositioning metal wire into the desired near-net-shape precisely.

  • Open articulated robot systems are the most flexible and can be modified to fit each application’s specific needs.
  • Enclosed cartesian systems offer the highest positional accuracy and process control.
  • Tool attachments can transform existing equipment into a hybrid, additive, and subtractive system.

Welding

In principle, every welding process can be used with WAAM.

In practice, these three welding processes are used mostly:

  • MIG (GMAW): offers the largest deposition rates, typically used to manufacture large parts built in an open atmosphere, easy to implement and low cost of equipment.
  • CMT: a variation of MIG with lower desposition rate offers closer process control and a smaller probability of thermal defects.
  • TIG (GTAW): offers higher welding quality than MIG at lower welding speed due to the need to rotate the wire feeding mechanism during processing.

MetalXL

Control Systems

The software that controls the WAAM System dictates all process operations and ensures that the part is manufactured as intended.

It includes:

  • Tool path generation to convert designs into machine instgruction and printing strategies.
  • Robot kinematics control to transform all programming into physical motions.
  • Sensors for safe and efficient operations to ensure high-quality prints.

M1 METAL AM SYSTEM

Built on extensive experience with >20,000 kg printed metal at MX3D, M1 offers a full solution to get started with robotic WAAM fast and print high-quality industrial metal parts in-house. 

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