Global supply chains are volatile. Geopolitical tensions, logistical bottlenecks, and supplier failures have shown just how quickly traditional, forecast-based procurement models are buckling under pressure. For companies in sectors like machine building, energy, and shipbuilding, the question is more pressing than ever: How do we get the critical metal parts we need without waiting for months on end? The answer lies in a fundamental shift away from waiting and toward agile, on-demand manufacturing.
WAAM: Creating Metal Parts Directly from Digital Data
This is where Wire Arc Additive Manufacturing (WAAM) comes in – a technology that’s redefining value chains. WAAM is an additive process that fuses proven welding technology with precise CNC control. Instead of milling a part from a solid block of metal, it’s built layer by layer from cost-effective metal wire.
The core of our solution is a true CNC machine that harnesses this additive process. For maximum precision and process reliability, we rely on an end-to-end Siemens ecosystem: machine programs are created in Siemens NX and flawlessly executed by the Sinumerik One controller. This approach allows for the production of massive metal components at impressive deposition rates of up to 5 kg per hour. Because the process creates a near-net-shape, the resulting part is already extremely close to the final product.
The biggest advantage? The entire process is tool-free. Expensive casting molds and forging dies, which can take months to produce, are eliminated entirely. This makes manufacturing highly cost-effective, even for a single part.
Strategic Advantages: It’s About More Than Just Speed
Switching to WAAM frees you from the unpredictability of long supply chains and offers real, strategic benefits:
- Drastically Shorter Lead Times: A forged part that typically takes 12 to 18 months can be produced with WAAM in just a few weeks or even hours, depending on the component. A lead time reduction of over 90% isn’t a future goal – it’s a current reality.
- From Physical Warehouses to Digital Inventories: Instead of tying up capital in expensive physical spare parts, you simply maintain a library of certified CAD files. When a part is needed, it’s printed on demand. This “digital inventory” minimizes costs and eliminates the risk of obsolete stock.
- Decentralized, On-Demand Manufacturing: Produce parts wherever you need them – on-site at your plant, in the shipyard, or at a maintenance depot. This boosts your independence and dramatically reduces risks from the global supply chain.
- Superior Material and Cost Efficiency: When a titanium part is machined traditionally, over 90% of the expensive raw material can be wasted (a buy-to-fly ratio of over 10:1). WAAM, an additive process, cuts that material loss to less than 10% (a buy-to-fly ratio under 2:1), leading to massive savings in both cost and resources.
- Incredible Material Flexibility: Essentially, any weldable metal wire can be used. This opens up a vast range of applications with industry-critical materials like titanium alloys (e.g., Ti-6Al-4V), steels, nickel-based superalloys (e.g., Inconel 625), and bronze alloys.
Industrially Proven: WAAM in Action
WAAM’s viability isn’t just theoretical – it’s backed by major industry case studies:
- The Energy Sector (Siemens Energy): When faced with a supply chain crisis for steam turbine guide vanes, Siemens Energy turned to WAAM. The result was complete independence from their supplier and the successful serial production of over 2,000 critical components – a milestone proving the technology’s industrial maturity.
A Realistic Look: The Hybrid Process
WAAM is an incredibly powerful method for creating the initial near-net-shape form. To achieve the highest levels of precision, the final component is the result of a hybrid process. The additive build is often followed by heat treatment (stress-relief annealing) for mechanical integrity and a final CNC machining pass for perfect tolerances and mating surfaces. In this workflow, WAAM and subtractive manufacturing work hand-in-hand.
Conclusion: Redesign Your Supply Chain
In an era where resilience and agility are everything, WAAM is more than a manufacturing technology – it’s a strategic tool. It allows you to build a new, agile production ecosystem that frees you from volatile global markets. Instead of waiting for months, you can produce critical parts yourself in a matter of weeks, minimizing downtime, cutting costs, and maximizing your operational flexibility.
