Does the future of WAAM lie in making it boring?
Two DEEP Manufacturing engineering managers share their thoughts on qualification, standards and wider industrial adoption.
As Wire Arc Additive Manufacturing (WAAM) transitions into wider industrial use, qualification, standards and a clear understanding of where the technology adds value are becoming increasingly important.
At DEEP Manufacturing’s Houston and Bristol facilities, Hannah Sims and Victoria Sharpe approach these areas from different perspectives. Hannah brings a background in materials science, WAAM research and qualification, while Victoria draws on experience across automotive and medical device manufacture to lead DEEP Manufacturing’s engineering teams.
We spoke to them about what could drive wider adoption of WAAM, how qualification and standards need to adapt, where the technology could have the greatest impact and whether the future of WAAM lies in making it ‘boring’.
What will drive wider adoption of WAAM?
“I think the biggest thing that’ll accelerate industry-wide adoption is probably qualification. That’s one of our biggest barriers right now.” - Hannah
As understanding of the WAAM process continues to grow, focus is turning towards qualifying it for production parts, and this is a major feature of Hannah’s work at DEEP Manufacturing Houston.
Victoria sees another potential driver in the speed and flexibility WAAM can offer compared with conventional manufacturing:
“WAAM can deliver parts a lot quicker than conventional manufacturing techniques, particularly castings and forgings.”
Without the need for additional tooling, WAAM can make engineering changes faster. And the flexibility of the additive manufacturing process also means it can have a role in both one-off components and higher-volume manufacturing, depending on the application.
Building confidence through standards and qualification
If qualification is one of the barriers to wider adoption, standards have an important part to play in establishing how WAAM components can be assessed and approved.
Hannah sits on the ASTM F42 committee focused on standards creation in additive manufacturing, giving her first-hand insight into how standards are evolving. She says “ensuring that we’re making standards that get us the parts that will work but not making standards so difficult that we’ll never meet them, is something I think is really important.”
Victoria also sees standards as key to building customer confidence. However, she explains that “WAAM is different to traditional welding where two solid plates are welded together, it’s a part fully made up of weld.” That means existing standards cannot always be applied directly to WAAM, and qualification routes need to reflect how these components are actually produced.
Customer requirements are also a key consideration. Victoria points out that components are often specified around the materials available when they were originally designed, and WAAM creates an opportunity to revisit those decisions by considering different materials, thicknesses or profiles while still achieving the required mechanical performance.
The qualification process is another area that may need to evolve. For example, some current qualification requirements involve producing a sacrificial component for testing. However, as confidence in qualified parameters and test samples grows, Victoria believes there is opportunity to reduce that requirement by moving towards process qualification instead of part-specific qualification.
Where could WAAM have the greatest impact?
WAAM is not a replacement for every manufacturing process or every type of component. In fact, with weld beads typically around 5–10mm in width, Victoria sees it as particularly well suited to larger structural parts, including those subjected to significant forces in service.
Hannah sees particular potential where conventional manufacturing capacity and long lead times are already creating supply-chain challenges. In US defence, for example, she has encountered castings and forgings with procurement lead times of two to three years.
The opportunities are certainly not limited to defence. Between them, Hannah and Victoria see potential applications across sectors including maritime, energy, automotive and aerospace, providing the component is a good fit for the process.
“There are lots of different industries where we could help; it’s just finding the right applications.” – Hannah.
Meet the engineers behind the technology
Hannah’s route into WAAM began with chemistry. After completing her undergraduate degree, she wanted to move towards engineering and a more hands-on approach to solving problems. That led to a master’s and PhD focused on the fracture and fatigue behaviour of materials before eventually working with wire Directed Energy Deposition (DED).
An extended internship with a WAAM company, as well as time at a national laboratory, followed before Hannah joined DEEP Manufacturing, Houston. Today, qualification is a major part of Hannah’s role alongside supporting the development of the facility and its manufacturing capability.
Making WAAM ‘boring’
So, what does success look like for WAAM over the next few years?
For Hannah, it’s about making it boring.
“Casting is boring and casting is well known. So, I think we need to get to a place where WAAM’s boring too, and people aren’t scared to use it simply because it’s a different manufacturing process.”
In practice, that means reaching a point where choosing WAAM no longer attracts attention simply because it is WAAM. Continued progress in qualification, standards and process understanding will all contribute to getting there.
Victoria expects that growing confidence in WAAM will actually change how engineers approach the technology. Rather than adapting components originally designed for other manufacturing methods, she expects more parts to be specifically designed for the process.
For both engineers, wider adoption ultimately comes down to understanding where WAAM makes engineering and commercial sense and having the qualification routes and manufacturing confidence to use it there.
Could WAAM offer a new manufacturing route for your company? Speak to an expert to discuss your application and explore what’s possible.
Related publications
What is Wire Arc Additive Manufacturing (WAAM)?
Wire Arc Additive Manufacturing (WAAM) is a form of metal 3D printing used to produce large-scale metal components. Instead of removing material from a solid block, WAAM builds parts layer by layer by melting metal wire with an electric arc.
What does ‘industrial readiness’ actually mean for DED?
Directed Energy Deposition (DED) has progressed considerably over the past decade, with qualified applications now demonstrating its potential across aerospace, defence, energy and maritime. But proving that the technology can produce a component is only part of the picture. Josh Barras, Additive Manufacturing Principal Engineer at ASTM International, explores what industrial readiness really means for DED and what needs to happen next.