How does WAAM compare to traditional manufacturing methods for large parts?

Lead Time and Production Speed

Wire Arc Additive Manufacturing (WAAM) offers dramatically shorter production times compared with traditional forging, casting, or machining. Large components such as turbine cases, aerospace structural frames, and pressure housings typically require long lead times when produced via vacuum investment casting or forging due to tooling preparation, mold fabrication, and material processing cycles. WAAM eliminates tooling entirely and deposits material at high build rates, reducing lead times from months to weeks—even for meter-scale high-temperature alloy parts.

Material Efficiency and Waste Reduction

Traditional machining from billet or forging stock generates substantial waste, especially when producing complex or hollow structures. WAAM builds near-net-shape geometries with minimal material removal required afterward. Using cost-effective wire feedstock, WAAM minimizes scrap—an important advantage for expensive superalloys like Inconel, Hastelloy, and titanium alloys commonly used in superalloy additive manufacturing. This translates into significant cost savings for industries relying on large, high-value parts.

Manufacturing Scale and Design Flexibility

WAAM is not constrained by the chamber size of powder-bed 3D printing systems. It can manufacture multi-meter components and integrate complex design features without the need for welding assemblies or joining multiple sections. Traditional forging or casting may require segmented production and subsequent joining, which introduces structural discontinuities. WAAM enables monolithic structures with continuous microstructures, improving strength and durability for large parts used in aerospace, marine, and energy applications.

Mechanical Performance and Post-Processing

While forging still provides excellent mechanical properties, WAAM components can achieve comparable performance when paired with post-processing steps such as HIP, heat treatment, and finishing via CNC machining. WAAM also allows localized reinforcement or repair—capabilities that traditional methods cannot match without reworking or replacing the entire component.

Cost Structure and Industrial Impact

WAAM significantly reduces cost for large-scale production by removing the need for forging dies, casting molds, long machining cycles, and material overstock. Industries such as power generation, oil and gas, and heavy marine manufacturing benefit from the ability to fabricate or restore large parts quickly, economically, and with excellent metallurgical performance.