When people first hear about Wire Arc Additive Manufacturing (WAAM), one of the most common follow-up questions is simple: “What metals can you actually use with this process?” The answer is both straightforward and powerful: any metal that can be welded can be printed with WAAM.
This material flexibility is one of the core strengths of WAAM and a key reason why the technology is gaining traction in industrial sectors like energy, maritime, manufacturing, and aerospace. It allows engineers and production teams to work with proven materials, simplify sourcing, and produce parts that meet existing standards, all while taking advantage of the speed and freedom that 3D printing offers.
Let’s explore which materials are most commonly used, how WAAM fits into the broader category of Directed Energy Deposition (DED), and why feedstock matters when choosing the right AM technology.
WAAM Is a Subset of Directed Energy Deposition (DED)
Before diving into materials, it helps to understand where WAAM fits in the world of metal additive manufacturing. WAAM is a specific type of Directed Energy Deposition (DED), an AM category defined by the use of focused energy (like an arc or laser) to melt and deposit material, layer by layer.
While some DED processes use powdered feedstock delivered through nozzles and fused by lasers or electron beams, WAAM specifically uses metal wire as its input, melted using an electric arc. This welding-based approach is closer to traditional fabrication methods, which makes it especially appealing for industrial users.
In many contexts, the terms WAAM and DED are used interchangeably, especially when describing wire-fed DED systems. However, WAAM is distinct in that it typically uses arc welding technology (such as MIG or TIG), combined with multi-axis robotic motion for precise deposition of large parts.
Now, onto the materials.
Common Materials Used in WAAM
The basic rule of WAAM is: if it can be welded, it can be printed. That opens the door to a wide range of engineering metals, many of which are already certified and widely used in industrial production. These include:
1. Stainless Steels (e.g., 316L, 308L)
Stainless steels are among the most widely used materials in WAAM. Alloys like 316L are known for their corrosion resistance and toughness, making them ideal for applications in maritime, chemical, and food industries. WAAM-printed stainless steel parts have demonstrated excellent mechanical properties and surface finish after standard post-processing.
2. Structural Carbon Steels
For large structural components, mild steel and low-alloy steels are often the material of choice. These steels are cost-effective, strong, and easy to process. WAAM can be used to build up complex geometries in structural steel with relatively little finishing, which is ideal for infrastructure, heavy equipment, or manufacturing tooling.
3. Nickel-Based Alloys (e.g., Inconel 625, Inconel 718)
Inconel alloys are prized for their strength and resistance to heat, corrosion, and oxidation. WAAM allows users to print large Inconel components for aerospace, offshore, or high-temperature applications without the extreme cost associated with powder-based AM processes.
4. Aluminum Bronze and Copper Alloys
Although pure aluminum is challenging due to its high thermal conductivity and oxidation behavior, aluminum bronze has proven effective in WAAM applications. It offers good wear resistance and anti-corrosion properties, making it useful for bushings, marine bearings, and decorative applications.
5. High-Strength Low Alloy (HSLA) Steels
HSLA steels combine strength and toughness and are commonly used in the defense and energy sectors. These materials can be printed using WAAM, offering a path to producing critical load-bearing parts with reduced lead time.
6. Other Custom or Experimental Alloys
Because WAAM uses standard welding wire as feedstock, companies and research institutes can experiment with custom alloys more easily than with powders. This opens up innovation in metallurgy, allowing for tuned properties without the high cost or safety concerns of powder handling.
Advantages of Wire Feedstock Compared to Powder
The use of wire feedstock gives WAAM a practical edge over many other metal AM processes, particularly when it comes to material handling, cost, and availability. Here are a few reasons why:
- Availability: Welding wire is a global standard, easily sourced in a wide range of compositions and diameters. There’s no need to rely on niche suppliers for custom powders.
- Cost: Wire is significantly cheaper than AM-grade metal powder, often by a factor of 3 to 10, depending on the alloy.
- Safety: Unlike powder-based processes, wire feedstock does not pose a risk of inhalation or dust explosion. This simplifies installation and compliance with health and safety regulations.
- Sustainability: Wire has a low material waste factor and is easier to recycle or reuse compared to powders, which can degrade over time or become contaminated.
These factors make WAAM a more accessible and scalable solution for manufacturers who want to produce large, high-performance parts without the complexity of vacuum chambers or powder handling systems.
Material Performance and Certification
One common question is whether WAAM parts made from standard welding wires meet the same mechanical properties as traditionally forged or machined parts. The answer is increasingly yes when the process is controlled properly.
Using software like MX3D’s MetalXL, it is possible to log and control heat input, layer height, temperature, and deposition parameters with precision. Combined with post-processing such as machining and heat treatment, this enables WAAM parts to meet certification standards such as:
- ISO 9001
- ASME Section IX
- API standards for offshore applications
- Client-specific aerospace or energy sector certifications
Mechanical testing of printed parts shows that strength, ductility, and fatigue performance can all match or exceed those of cast components, especially for alloys like 316L and Inconel.
Choosing the Right Material for Your WAAM Project
Material selection in WAAM is driven by the same considerations as traditional metal fabrication: performance requirements, environmental exposure, mechanical loads, corrosion risks, and cost. Because WAAM can work with the same alloys you’re already using in welding, the transition is often seamless.
Whether you’re building a pressure-retaining part for the oil industry, a corrosion-resistant bracket for a ship, or a structural arm for a manufacturing line, there’s likely a proven welding wire and a WAAM profile to match.
At MX3D, we help clients navigate this selection process based on application, certification, and scalability. Our engineers optimize both the material and process parameters to ensure each component is printed with repeatable quality, ready for real-world use.
Conclusion: Material Versatility Makes WAAM an Industrial-Ready Solution
Wire Arc Additive Manufacturing stands out in the world of metal 3D printing because of its unmatched material versatility. By working with standard welding alloys, it bridges the gap between additive flexibility and industrial practicality.
As a form of Directed Energy Deposition, WAAM combines the freedom of 3D design with the robustness of arc welding and the scalability of wire-based production. Whether you need stainless steel, Inconel, structural steel, or custom alloys, WAAM offers a fast, certifiable, and cost-effective way to build high-performance metal parts.
If you’re exploring WAAM and unsure which material fits your needs, MX3D can guide you. from initial feasibility to full-scale production. Let’s start building.
