WAAM3D’s new RoboWAAM XP expands size, mass and speed
WAAM3D, a leading Wire Arc Additive Manufacturing (WAAM) innovator, launched the 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, aluminum, 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.
New extended build platform
This advanced robotic system features a 6-axis robot arm paired with a 2-axis part rotator, delivering exceptional precision with a repeatability of ±0.05 mm. It boasts a spacious working envelope of 2 m x 2 m x 2 m, accommodating diverse applications, while its compact overall dimensions of 5.8 m (width) x 5.2 m (depth) x 4.3 m (height) make it suitable for efficient space utilization.
The system is equipped with a vision-based monitoring setup for current, voltage, and melt pool tracking, ensuring optimal process control. Integrated software solutions like WAAMPlanner and WAAMCtrl further enhance operational efficiency and control. Optional features include a fume management system for cleaner operations, pyrometry for consistent temperature maintenance, and laser interferometry for real-time monitoring and automatic correction of layer height errors, making this robotic system a versatile and reliable solution for industries demanding precision and adaptability.
RoboWAAM XP features
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 deposited for the same energy input. The addition of a non-energized wire greatly stabilizes 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.”
