Whether for spare parts, prototypes or complex one-off components, Wire Arc Additive Manufacturing (WAAM) is emerging as an important industrial production process. Fronius’ new WAAM-based Additive Cell combines advanced CMT welding technology, intelligent process control and user-friendly software to produce high-quality metal components faster, more efficiently and with greater flexibility. With this innovation, Fronius further strengthens its position as a comprehensive solutions provider for additive manufacturing.

Additive manufacturing gains industrial momentum

Modern manufacturing processes are facing growing demands for shorter development cycles, improved material efficiency and cost-effective production of complex geometries. Industries such as aerospace, automotive, pressure vessels, rolling stock, and oil and gas increasingly require customised solutions and quickly available spare parts, creating opportunities for additive manufacturing.

Metal 3D printing enables components to be created virtually from digital designs. Compared with conventional manufacturing methods such as casting, cutting and milling, additive manufacturing reduces material consumption and production costs. “WAAM enables decentralised, location-independent manufacturing without the need for complex production lines. Even irregular geometries can be built to the highest quality standards without wasting valuable material,” says Manuel Stinglmayr, Business Development, Fronius International GmbH.

A stable welding process that enables consistent layer formation is critical for achieving quality in Directed Energy Deposition-Arc (DED-Arc) applications. The CMT Additive PRO, based on Fronius’ Cold Metal Transfer (CMT) process, is designed for additive manufacturing with a relatively cool dip transfer arc process that combines high deposition rates with low heat input.

The “CMT Additive PRO” welding characteristics are tailored specifically for additive manufacturing requirements. Features such as a deposition rate stabiliser, Pulsed HotStart, CTWD measurement and power correction help ensure process stability. “The CMT Additive PRO guarantees uniform and, above all, predictable layer build-up across the entire component. This significantly reduces scrap rates and the workload required for rework,” adds Stinglmayr.

Fronius Additive Cell enables flexible production

For many organisations, additive manufacturing presents several challenges. Compared with traditional manufacturing techniques, it significantly reduces material waste while eliminating the need for complex moulds, tools and long lead times. The new Fronius Additive Cell enables companies to begin component production quickly through a fully integrated system developed for industrial requirements.

Within the welding cell, the CMT Additive PRO and Fronius iWave ensure precise welding operations, while the Polaris system manages overall control. “The Additive Cell combines proven welding technology, intelligent control and Fronius’ extensive welding expertise. Every component has been designed to complement the other, resulting in a stable manufacturing process,” says Anna Dieplinger, Key Product Manager Additive Manufacturing, Automation & Digital Solutions, Fronius International GmbH.

The Fronius Additive Cell includes hardware as well as the company’s proprietary Vectris software suite, which integrates the machine tool service kit (MTSK) and post-processor on a central platform. Developed specifically for additive manufacturing applications, the software includes an integrated kinematic model, adapted user interface and validated welding operations.

The system also supports geometry-based identification of different component regions, allowing flexible process parameters for outer walls, panels, infills and component joints. Through the “FroArc” welding command integrated into the post-processor, these build styles are converted directly into robot welding code, enabling automatic switching between welding parameters at precise locations.

Fronius’ integrated solution, combining welding equipment and software, enables a simple, stable and reliable additive manufacturing process.

360° service for additive manufacturing applications

The applications of the Fronius Additive Cell and WAAM extend from reverse engineering and optimisation of existing components to developing completely new designs. Reverse engineering is particularly valuable for repairs where original parts are unavailable or CAD data has been lost, while new designs enable improved geometries and enhanced manufacturing efficiency.

To support these requirements, Fronius provides consultation, feasibility studies, process development and production services through its Prototyping and Manufacturing Center. The company also develops, tests and certifies welding and pressure parameters for different materials. These validated process “recipes” can be licensed directly, allowing customers to begin production without delays.

As part of its 360° service offering, Fronius can also manage complete process engineering for additive manufacturing projects. Customers benefit from the company’s technical expertise, development capabilities and tested solutions while reducing implementation risks.

With decades of experience in welding technology, Fronius has established a strong foundation for industrial additive manufacturing. The continued advancement of CMT technology, combined with application expertise and process knowledge, positions Fronius as a partner for diverse additive manufacturing requirements.