Wire Arc Additive Manufacturing (WAAM) is a Directed Energy Deposition (DED) process that uses an electric arc as the heat source and metal wire as feedstock to build parts layer by layer. It combines conventional arc welding technology (MIG, TIG, or plasma) with robotic or CNC motion control.

WAAM offers several advantages over powder-based metal AM processes:

• High deposition rates: 1-10 kg/hour, significantly faster than powder-bed processes
• Large build volumes: Parts can exceed several meters in dimension
• Lower material costs: Standard welding wire is far cheaper than metal powder
• Material efficiency: Near-net-shape production reduces machining waste

Common materials include steel, stainless steel, aluminum, titanium, nickel alloys, and bronze. Post-processing typically involves CNC machining to achieve final tolerances and surface finish.

• Deposition Rate 1-10 kg/hour
• Build Volume Limited by robot reach (typically 1-3m)
• Layer Height 1-3 mm
• Wall Thickness 3-8 mm minimum
• Surface Finish (as-built) Ra 200-500 µm

• Directed Energy Deposition
• Wire Arc Energy Deposition
• ARCEMY

• RAMLAB - WAAM 101
• TWI - Arc-based Additive Manufacturing