Welding system manufacturer Fronius has introduced its new Wire Arc Additive Manufacturing (WAAM)-based Additive Cell for the production of high-quality metal components.
WAAM is becoming increasingly utilised for 3D printed spare parts, prototypes and complex one-of-a-kind components, as modern manufacturing requires ever shorter development cycles, increased material efficiency and complex geometries. Fronius’ Additive Cell is engineered to meet these requirements for high-quality metal parts, combining state-of-the-art CMT welding technology, intelligent process control and user-friendly software.
In recent years, additive manufacturing has enabled greater customisation, tailored solutions, and spare parts that are available quickly for industries such as automotive, aerospace and oil and gas. Compared to conventional manufacturing processes such as casting, cutting, or milling, additive components keep material consumption and costs low.
“WAAM enables decentralised, location-dependent manufacturing without the need for complex production lines,” said Manuel Stinglmayr, business development at Fronius International. “Even irregular geometries can be built to the highest quality standards without wasting valuable material.”
Fronius’ additive technology
A stable welding process that enables uniform layer build-up is crucial for achieving the desired quality with the Directed Energy Deposition-Arc (DED-Arc) method. The CMT Additive Pro, which is based on the Cold Metal Transfer (CMT) process developed by Fronius, is particularly well-suited to additive manufacturing as a relatively cool dip transfer arc process that combines a higher deposition rate than other additive manufacturing methods with low heat input.
The CMT Additive Pro provides tailored features such as deposition rate stabiliser, Pulsed HotStart, CTWD measurement and power correction to ensure necessary process stability.
Stinglmayr added: “The CMT Additive Pro guarantees uniform and, above all, predictable layer build-up across the entire component. This drastically reduces scrap rates as well as the workload required for any rework.”
The Additive Cell
Fronius’ new Additive Cell focuses largely on speed. The coordinated system is designed to meet the needs of various demanding industries. Inside the welding cell, the CMT Additive Pro and Fronius iWave ensure a precise welding process while the Polaris system remains in overall control.
“The Additive Cell combines proven welding technology, intelligent control and Fronius’ many years of welding expertise,” said Anna Dieplinger, key product manager additive manufacuring, automation & digital solutions at Fronius International. “Every component has been designed to complement the other, resulting in a stable manufacturing process.”
The Additive Cells features the company’s proprietary software bundle, Vectris, which brings together the machine tool service kit (MTSK) and post-processor on a single central platform. In addition to an integrated kinematic model, an adapted user interface, and validated welding operations for additive processes, Vectris also supports geometry-based detection of different component regions. This allows for flexible process parameters, such as different settings for outer walls, panels, infills, or component joints.
The post-processor is integrated with the FroArc welding command, which translates these build styles into code for the system’s welding robot, allowing it to switch to the correct welding parameters at the desired location without delay. The integrated system enables a simple, stable and reliable welding process for metal parts.
360-degree service for AM
Fronius’ Additive Cell and its integrated WAAM technology has applications ranging from reverse engineering and optimisation of existing components to entirely new designs. Fronius offers consultation, feasibility studies, process development and production services at its prototyping and manufacturing centre, to assist customers with their requirements.
The company can also develop, test and certify the optimal welding and pressure parameters for various welding materials as ready-made, validated ‘recipes’, which it can license directly to its customers.
