WAAM3D, a leader in Wire Arc Additive Manufacturing (WAAM) technology, has unveiled its latest innovation, the RoboWAAM XP, at Formnext 2024. Designed for large-scale metal additive manufacturing, the RoboWAAM XP integrates Cranfield University’s patented Cold-Wire Gas Metal Arc (CWGMA) process, enabling deposition rates of up to 15 kg per hour without compromising quality or precision.
This advanced system, developed since 2018 and tested over the past two years, expands WAAM3D’s capabilities to meet industrial demands for large, complex metal parts with shorter lead times.
Expanding Capacity and Flexibility
The RoboWAAM XP features a build envelope of 2 x 2 x 2 meters and supports a maximum payload of 2.1 tonnes, making it ideal for industries requiring robust, large-scale components. Its 8-axis motion capability ensures it can handle geometrically complex designs regardless of payload size.
The system works seamlessly with a variety of high-performance alloys, including iron, aluminum, nickel, and copper. In addition to CWGMA, it supports MIG, MAG, and CMT welding processes through Fronius technology, offering unparalleled flexibility for manufacturers.
Boosting Productivity and Precision
The CWGMA process enhances productivity by significantly increasing deposition rates while maintaining energy efficiency. This innovation enables faster manufacturing without sacrificing quality or precision. The system integrates with WAAM3D’s proprietary WAAMPlanner for tool path planning and WAAMCtrl for process monitoring, ensuring ease of use and consistency across projects.
Users familiar with WAAM3D’s existing systems will find the RoboWAAM XP workflow intuitive, with additional tools for data logging, visualization, and real-time process adjustments.
Technical Highlights of RoboWAAM XP
- 6-axis robot arm and 2-axis part rotator with ±0.05 mm repeatability.
- Build envelope: 2 x 2 x 2 meters.
- Overall dimensions: 5.8 x 5.2 x 4.3 meters.
- Monitoring and control tools: Current, voltage, and melt pool tracking via a vision system.
- Optional features: Fume management, pyrometry for consistent temperatures, and laser interferometry for real-time layer height monitoring and corrections.
Industry Impact and Vision
Dr. Jialuo Ding, CTO of WAAM3D, highlighted the significance of the RoboWAAM XP launch, stating, “This fully integrated system delivers higher productivity while maintaining precision and control. It represents a pivotal moment for additive manufacturing, offering solutions to meet growing industrial demands for efficiency and quality.”
Co-founder and Technical Director Stewart Williams, who is also a professor at Cranfield University, emphasized the innovation behind CWGMA technology: “The addition of a non-energized cold wire to the GMA process nearly doubles material deposition rates without additional energy input. This stability broadens material compatibility while allowing microstructure adaptations to meet specific property requirements.”
A Step Forward for Large-Scale Additive Manufacturing
The RoboWAAM XP reflects WAAM3D’s commitment to pushing the boundaries of large-format additive manufacturing. By combining advanced deposition rates with precision control, the system addresses the increasing demand for large-scale metal parts across sectors such as energy, space, marine, and mining.
As industries seek to reduce lead times and enhance material efficiency, WAAM3D’s latest system offers a powerful tool for scaling production while maintaining stringent quality standards.
Source: metal-am.com