Bringing Large-Scale WAAM into Production in the US
For years, large-scale additive manufacturing has been positioned as a technology with significant potential. The ability to produce complex, high-integrity metal components with reduced lead times and greater design freedom has been well understood and anticipated.
Yet across industries such as energy, defence and subsea, adoption has been slower than expected. Not because the technology lacks capability, but because integrating it into real-world production environments has remained a challenge, particularly when it needs to sit alongside well-established supply chains and traditional manufacturing methods.
That is now beginning to change. With the launch of our Houston facility, DEEP Manufacturing is bringing industrial-scale Wire Arc Additive Manufacturing (WAAM) capability closer to the sectors where it can be applied in production.
The site represents more than an expansion of footprint. It marks a step forward in applying industrial-scale additive manufacturing in production environments, where certification, delivery timelines and supply chain reliability are critical.
With four WAAM systems already operational and further expansion planned, the facility is production ready. Early test builds have already been completed, and we are demonstrating that this is not a future capability, but one that is available now.
A more practical manufacturing route
WAAM offers a different approach to producing large, complex metal components.
By building near-net shape parts and combining additive manufacturing with machining and finishing processes, there can be a significant impact on delivery. For example, a large steel casting that might typically take around 18 weeks can, in some cases, be produced in closer to six weeks using DED-Arc (WAAM).
It also creates a more streamlined supply chain, with fewer handoffs between suppliers and greater accountability for delivery.
Designed to integrate with industry
Adoption of additive manufacturing has often been slowed by the challenge of integrating it into existing ways of working.
WAAM is increasingly being used alongside traditional manufacturing rather than replacing it entirely. This hybrid approach allows companies to introduce additive manufacturing in a way that is practical and lower risk.
DEEP Manufacturing supports this through our engineer-to-engineer approach, working from material requirements and performance specifications through to production and certification.
The Houston facility is being developed to operate under the same DNV Approval of Manufacture (AoM) framework as the Bristol UK site , including for pressure vessels for human occupancy (PVHOs). This provides a recognised route to certification for safety-critical components, helping to build confidence in the use of WAAM within demanding applications.
By providing a fully integrated, certified manufacturing service, the complexity of adoption is reduced. Customers can access the capability without needing to invest in systems or qualification themselves.
Closer to the point of use
Houston is one of the world’s leading hubs for energy, subsea and industrial engineering. Locating the facility here allows DEEP Manufacturing to work more closely with the industries where WAAM can deliver the most immediate value.
It also strengthens the ability to deliver components within shorter timeframes through our skilled workforce, reducing reliance on extended supply chains and improving responsiveness to customer demand.
Combined with operations in the UK, the Houston facility forms part of a growing global capability to support customers across multiple regions.
From capability to application
The launch of the Houston facility reflects a broader shift in how large-scale additive manufacturing is being used.
WAAM is no longer confined to demonstration or niche applications. Rather, it is being applied to real components in production environments, where it can deliver measurable improvements in lead time, flexibility and supply chain resilience.
For industries under pressure to deliver faster and with greater certainty, that shift matters - and it is already underway.
Houston’s official launch event takes place on May 6th. If you would like to attend, please contact us to register your interest. At the event, you will be able to see large-scale components up close, watch a part in print, and speak to our team of experts.
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