• Datum: 2023-11-28 13:01:54
• Firma: WAAM3D Limited
• Ansprechpartner: Mr Filomeno Martina
• E-Mail: filo@waam3d.com
• Anschrift: 5 Thornton Chase, MK146FD Milton Keynes
• Telefon: 01908101030
• Land: United Kingdom
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WAAM3D is a Cranfield University spinout company leveraging on almost 30 years of academic research and development. The founding team has been at the forefront of large-scale metal additive manufacturing (AM) demonstrating feasibility of the largest structures ever produced. These include primary titanium fuselage components for fighter jets, landing gear ribs, wing spars, wing ribs, propellant tanks, water tanks, armoured panels, weapon systems, rocket motors, engine casings, gas turbine blades, runners, and many others.

Within large-scale metal AM, WAAM3D provides the only end-to-end software solution covering computer aided manufacturing, to machine and process control, to post-build data analytics.

RoboWAAM, their award-winning state-of-the-art large format printer, has the largest number of sensors and the most advanced process monitoring and control in the industry. It goes above and beyond what standards and certification bodies demand, providing the highest level of confidence over the quality of the output produced.

WAAM3D also owns a patent on the in-process application of mechanical deformation, to achieve forged level of mechanical properties within additively made structures. This is by far the most robust method to enable like-for-like transition from incumbent wasteful manufacturing processes to the more modern additive approach.

WAAM3D has received awards for Aerospace Application of the Year in 2019, Best 3D Printing Hardware in 2022, and recently ATI Breakthrough award for the start-up company with the most potential to impact aerospace and to support the journey to net zero 2050 for commercial flight.

What makes WAAM3D so interesting? The answer lies in the waste reduction potential, in the Kaizen-way: reduction of over-production, inventory, motion, defects, over-processing, waiting, and transport. This is key to make design, manufacturing, and support operations leaner and leaner, within a global context demanding the reshoring of manufacturing to mitigate supply chain risks; the protection of profit margins against inflation; the design of products for sustainability; and the faster launch of products. Enabling a “digital” process, capable of printing a part straight from its CAD file with little to no fixturing, WAAM3D can meet most of, if not all, these requirements. Lead times can be reduced from years to weeks. Material utilisation can be increased from as little as 2% up to 90%. Environmental footprint, measured by its proxy of Embodied Energy and equivalent CO2 emission, can be more than halved. Local manufacturing can be enabled affordably, lifting constraints on traditional supply chain, with lower barriers to entrance and more balanced negotiations. Inventory can be managed more flexibly, also thanks to the huge opportunity related to the use of WAAM3D technology not only for the production of spare parts, but also for repair and remanufacturing to extend the life of high-value assets.

As Carbon Fibre Reinforced Polymers use grew on modern aircrafts, so did the amount of titanium. In weight, Boeing’s 747 had 1% of CFRP and 4% of titanium; Airbus’ A350 53% and 14%, respectively. This explains why, in terms of number of demonstrators built, those in titanium alloys have received the largest interest, especially in Ti-6Al-4V (Ti64). This is thanks to the alloy’s cost, the difficulty in processing it (either when forged or machined), and the way parts are made traditionally, with huge fractions turned into low value swarf. Hence, the rise of an urgent need for an alternative manufacturing process.

The potential can be measured in terms of its current and forecasted size. Today, the global AM market is worth £15bn, and is expected to grow at 20.8% to reach over £60bn by 2030. Crucially, this figure represents only metal AM applications, and excludes the revenues associated with metal AM hardware, materials or software. Market revenues are estimated at $18b, $3b, and $11b for hardware, materials and services, respectively, by 2030. With specific regards to WAAM, cumulative machines sold forecasts 3,501 units. WAAM3D has the most advanced kit on the market, and is extremely well placed to seize this opportunity.

Extreme heat due to deposition of molten material
containment of highly critical equipment e.g. fibre optics

Long service life

we have been able to improve ergonomics of the machine and simplify installation of equipment at the customer site.

• Energy chain(s) TR.RSE.70

we have chosen Igus since the very beginning, since we installed our first machine.

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Material utilisation can be increased from as little as 2% up to 90%. Environmental footprint, measured by its proxy of Embodied Energy and equivalent CO2 emission, can be more than halved. Local manufacturing can be enabled affordably, lifting constraints on traditional supply chain.

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