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FEATURE ADDITIVE MANUFACTURING/3D PRINTING
MANUFACTURING TO THE
TAKING METAL ADDITIVE
NEXT LEVEL
From the small beginnings of the first 3D printing technique by Dr. Hideo Kodama in the early 1980s, the technology has come on in leaps and
bounds in recent years. Here Dr Filomeno Martina, CEO and co-founder of WAAM3D, discusses
how state-of-the-art 3D metal printing is being used today to great effect by manufacturers looking to produce or repair components
T
he global market for metal additive manufacturing of both large and small components was valued at USD 2.90 billion in 2022 and is expected to reach around USD 14.99 billion by 2032, growing at a CAGR of 17.90% from 2023 to 2032. This growth is being driven by increased demand for consumer electronics and such sectors as aerospace and automotive, that are looking to adopt more efficient, less resource-hungry manufacturing practices.
MANUFACTURING MEDIUM AND LARGE-SCALE COMPONENTS Directed Energy Deposition (DED) 3D printing techniques are generally preferred for the creation of larger sized components that have simpler geometry and for repairing large components. DED processes use a plasma/electric arc, electron beam or laser beam as a focused energy source to melt and direct the chosen metal, wire or powder material into a small melt pool that builds layer by layer into the component’s chosen form. One process in particular – Wire Arc Additive Manufacturing, or WAAM for short – has benefited from intensive research and now stands head and shoulders above the rest for medium- to large-scale component creation. WAAM uses an electric arc to melt wire
feedstock onto a metal base plate that is built up as the robotic head automatically moves the printing head backwards and forwards in a pre- programmed pattern. When used for construction or repair of large parts, WAAM can deliver
significant cost, material, waste, time, energy, and CO2
emission savings, compared to more
traditional forging, casting, CNC machining, or fabrication processes.
WAAM BENEFITS Quick production times: WAAM replaces long lead-time processes, such as forging and casting. The WAAM process allows a wide variety of metal feedstocks to be used and the deposition rates of the feedstock are relatively fast. For example, between 1kg/hr and 4kg/hr for aluminium and steel, making it possible to manufacture large structures within 12 to 24 hours. In addition, deposition rates
are only getting faster, with the HPWAAM (High Productivity Wire Arc Additive Manufacturing group) that WAAM3D is involved in increasing steel deposition rates to 15kg/h, from a baseline of 3kg/h, using a novel Wire Arc Additive Manufacturing (WAAM) process. Compare the WAAM process to the lengthy lead- times for forged parts, typically more than 12 months, with further delays incurred for rough and finish machining, and the benefits of opting for WAAM for creating larger parts become evident.
44 DESIGN SOLUTIONS NOVEMBER 2023
The Plasma Transferred Arc variant of WAAM3D’s End-Effector
Material, waste and cost reduction: WAAM minimises expensive material waste and this can be a particularly convincing reason to convert to the process in sectors such as aerospace, where expensive titanium is used to create large components. In fact, when it comes to reducing manufacturing waste, the buy-to-fly ratio (BTF) ratio for aero engine components can be as high as 25, but using WAAM the BTF is <2. As well as reducing expensive waste, WAAM is seen as a cost-effective Additive Manufacturing approach for component fabrication and can deliver cost savings of up to 70% compared to machining from solid. Recent examples from WAAM3D include the printing of outboard landing gear, made from titanium (Ti-6Al-4V), with cost savings of 70%, and a printed satellite propellant tank for space exploration that delivered 50% cost savings. Energy and CO2
reductions: WAAM can offer
manufacturers significant carbon emission and carbon footprint reductions. That is because wire production and wire deposition are relatively small contributors compared to traditional billet. WAAM’s sustainability benefits can be seen during a component’s initial creation and throughout its lifecycle. When WAAM3D assessed the environmental impact of aTi-6Al- 4V part with a final mass of approximately 50 kg, as made using traditional machining from billet, and by WAAM, the WAAM component demonstrated a 40% reduction in environmental impact compared to the demonstration part made using traditional, subtractive fabrication approaches. As more and more companies
The first WAAM full-scale prototype of a titanium pressure
vessel to be used in future manned missions for space exploration
WAAM3D
www.waam3d.com
begin to explore ways to improve the manufacturing efficiency of their medium-to-large scale engineering components, it is no wonder that WAAM is proving so popular.
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