AM SoftwareMetal Additive ManufacturingProcess Monitoring

WAAM3D releases WAAMCtrl v2 at TCT360

An updated version of the all-encompassing operating system for WAAM3D’s RoboWAAM

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WAAM3D, a global leader in Wire Arc Additive Manufacturing (WAAM), has released the second version of its signature WAAMCtrl software, at TCT360. The software has been under development since 2015. This all-encompassing operating system for WAAM3D’s RoboWAAM, a state-of-the-art multi-meter metal 3D printing platform, has been designed for aerospace, defense, energy, and research.

Leveraging the 60 sensors on board the RoboWAAM, WAAMCtrl monitors and controls the WAAM deposition, whilst recording all key process parameters on its secure server. As well as enabling operators to have a fully controllable production process, WAAMCtrl incorporates auditable data storage, quality logs, and interactive data navigation to demonstrate compliance in a repeatable way. Finally, via its ergonomic, touchscreen-based graphical user interface, the operator can initiate automatic cycles for shielding atmosphere establishment, maintenance, and evacuation. WAAMCtrl also provides a facility for controlling and restarting deposition programs.

WAAM3D releases WAAMCtrl v2 at TCT360 - an updated version of the all-encompassing operating system for WAAM3D’s RoboWAAM.
Split screen view to compare different key process variables side-by-side.

WAAMCtrl’s primary features include the process monitoring of voltage, current, wire feed speed, travel speed, wire position, layer height, pre- and post-deposition temperature, oxygen, gas flow, and melt pool – in combination with RoboWAAM’s hardware; database logging of all key process parameters data; real-time rendering of a 3D map of logged data onto actual tool path; industry 4.0-enabled with downstream big data analysis; and, via its API, it can be integrated with ERP and MRP systems for push to post-processes.

WAAMCtrl v2

The v2 updates include touchscreen operation; support for the newest WAAM3D processes: CWMIG and Dual-Wire-Plasma; support for new materials: Waspalloy and Inconel 718; support for in-process forging via vertical and lateral rolling; improved closed-loop control for automatic wire positioning for existing materials: Ti64 and carbon steel; improved in-process layer height measurement; pre-deposition thermal monitoring – allowing a specific interpass/interlayer temperature to be deployed, also resulting in minimized dwell time
Indicators showing the location of key sensors on the end-effectors; a Configurable Dashboard layout; and general improvements to the UI/UX, audit report, streaming and recording of the process camera, quality of life changes, and several bug fixes.

WAAM3D releases WAAMCtrl v2 at TCT360 - an updated version of the all-encompassing operating system for WAAM3D’s RoboWAAM.
One of WAAMCtrl’s touchscreen control interfaces for RoboWAAM, to manage inert atmosphere and deposition program execution.

Real-time control

Operators can see, in real-time, how a project is progressing thanks to the state-of-the-art sensors transmitting information to WAAMCtrl tens of times per second – for monitoring and control via proprietary wire-position and interpass temperature closed-loops. Real-time color-coding of the 3D charts also helps make sense of big deposition data, mapped over the part’s real geometry.

Evaluation

Should the production process need to be assessed, WAAMCtrl records all the process data, tracking the deposition of the part from material source to shipping and making them easily accessible. Thanks to WAAMCtrl’s use of statistical process control, its monitoring output enables the demonstration of robustness, validity, and compliance to certification boards and other regulatory bodies. All data can be summarised in the fully customizable Audit Forms or exported in CSV format.

WAAM3D releases WAAMCtrl v2 at TCT360 - an updated version of the all-encompassing operating system for WAAM3D’s RoboWAAM.
Another of WAAMCtrl’s touchscreen control interfaces for RoboWAAM, to monitor global shielding status.

“We are very pleased to be able to offer the v2 release of our signature WAAMCtrl software. WAAMCtrl serves as more than just a digital platform for collecting comprehensive process and system data for quality control purposes. It also offers a high level of process control and assists users in confidently utilizing the RoboWAAM system,” said Jialuo Ding, Co-founder, and Chief Technology Officer of WAAM3D.

The development of WAAMCtrl v2 has benefitted from funding from Innovate UK (part of UK Research and Innovation, driving productivity and economic growth by supporting businesses), within the HPWAAM project (£1.2m of funding, and grant number 53610).

Research
Composites AM 2024

746 composites AM companies individually surveyed and studied. Core composites AM market generated over $785 million in 2023. Market expected to grow to $7.8 billion by 2033 at 25.8% CAGR. This new...

Edward Wakefield

Edward is a freelance writer and additive manufacturing enthusiast looking to make AM more accessible and understandable.

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