WAAM3D, a leading innovator in the field of Wire Arc Additive Manufacturing (WAAM), is pleased to announce the launch of its new large format RoboWAAM® XP fully integrated system at Formnext this year. The solution contains Cranfield University’s cutting-edge, patented Cold-Wire Gas Metal Arc (CWGMA) process that enables superior deposition rates of up to 15 kilograms per hour, without compromising on the quality and precision required for high-performance materials. RoboWAAM® XP expands the size, and mass capabilities of the company’s family of integrated systems and works natively with alloys of iron, aluminium, nickel, and copper. It has been under development since 2018, and under industrial testing over the last two years with trusted partners in the energy, space, marine, and mining industries with impressive results.

Capacity and flexibility

Featuring a maximum build envelope of 2 x 2 x 2 metres, and a maximum payload of 2.1 tonnes, the RoboWAAM® XP  fully integrated system is ideal for manufacturing industries that have a requirement for large-scale spare parts with a short lead time. Besides the patented CWGMA process,  RoboWAAM® XP  ships with MIG, MAG, and CMT capabilities provided by Fronius and, thanks to its default 8 axes of motion, it does not compromise on the geometrical complexity that it achieves, irrespective of the size of the payload.

Boosting productivity and consistency

Cranfield University’s CWGMA process not only provides a high level of control but also enhances process efficiency by achieving higher deposition rates at the same energy input. The result is a significant boost in productivity through faster process speeds, whilst delivering in terms of quality and precision. Even with the integration of this new process into RoboWAAM® XP, the user experience remains familiar, mirroring the workflow of WAAM3D’s other integrated systems and technology packs.This is thanks to the use of WAAM3D’s WAAMPlanner® for tool path planning and process parameters allocation and WAAMCtrl® for process monitoring and control, and data logging and visualisation.

New extended build platform

RoboWAAM® XP features:

• 6-axis robot arm + 2-axis part rotator with robot repeatability of +-0.05mm
• A working envelope of 2 m x 2 m x 2 m
• Overall machine dimensions of 5.8 m (width) x 5.2 m (depth) x 4.3 m (height)
• Current, voltage, and melt pool monitoring via a vision system
• WAAMPlanner® and WAAMCtrl®
• Optional features include a fume management system, pyrometry for maintaining temperature consistency, and laser interferometry for real-time layer height monitoring and automatic corrections of layer height errors.

Dr Jialuo Ding, CTO of WAAM3D comments: “The introduction of WAAM3D’s latest, fully-integrated RoboWAAM® XP system offers users higher productivity, whilst maintaining precision and control. It is a testament to the partnership between WAAM3D and Cranfield University and our teams’ commitment to innovation and excellence in the field of additive manufacturing. The launch of RoboWAAM® XP is a pivotal moment in the industry, as it offers a solution that meets the growing demand for higher productivity, while maintaining the stringent quality standards necessary for advanced applications.”

Stewart Williams, one of the company’s founders, Technical Director at WAAM3D and a Professor at Cranfield University explains the secret to CWGMA’s success: “The key innovation with CWGMA is the addition of a non-energised cold wire to a conventional GMA process. Through this novel arrangement, high efficiencies can be obtained by nearly doubling the amount of material depositedfor the same energy input. The addition of a non-energised wire greatly stabilises the process, making it suitable for a very broad range of materials. With the unique level of control offered by CWGMA, there are also opportunities to adapt the microstructure to attain the desired properties.”

For more information concerning RoboWAAM® XP and CWGMA visit http://waam3d.com/hardware/robowaam-xp

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