What are the advantages of WAAM over traditional manufacturing methods?

WAAM vs. Traditional Manufacturing Methods

Wire Arc Additive Manufacturing (WAAM) offers key advantages over conventional methods such as forging, casting or machining. WAAM enables near-net-shape fabrication with significantly lower material waste, especially when producing large or complex superalloy and titanium components. For example, traditional machining of Ti-6Al-4V often results in high scrap rates, whereas WAAM can build the required geometry layer by layer with up to 90% material utilization.

WAAM is also advantageous for producing oversized aerospace or energy components that are difficult to cast or forge. Conventional processes may require expensive tooling and long lead times, while WAAM can generate large metal structures directly from CAD models, greatly reducing production time. When combined with post processes such as CNC machining or heat treatment, final accuracy and mechanical properties can match or exceed those of forged components.

Design Flexibility and Repair Capability

WAAM allows structural optimization through varying wall thickness, lattice forms and reinforcement zones, which traditional subtractive manufacturing cannot easily achieve. Furthermore, WAAM makes it possible to repair or modify high-value components instead of fully replacing them, which is particularly useful in aerospace and aviation or power generation equipment where downtime costs are critical. A damaged superalloy vane or casing can be rebuilt using WAAM and subsequently finished via CNC machining or heat treatment.

Material and Process Integration

WAAM is suitable for a wide range of alloys, including nickel-based grades such as Inconel 625, cobalt-based Stellite 6 and titanium alloys used in lightweight aerospace structures. By integrating WAAM with inspection and material testing and analysis, manufacturers can achieve repeatable quality while reducing cost and lead time compared with traditional manufacturing routes.