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.

WAAM is particularly well suited to low-volume, large-format component manufacturing, where traditional methods such as casting and forging can introduce long lead times, high material waste, and supply chain risk.

Once a design has been finalised, it can be programmed directly into WAAM robotic systems. This removes the need for tooling or moulds and allows production to begin sooner, significantly reducing lead times compared to conventional manufacturing routes.

Why use WAAM?

WAAM is often selected where scale, speed, and flexibility are critical.

By eliminating tooling and reducing material waste, WAAM provides a practical alternative for producing large components in low volumes. It also enables complex geometries that may be difficult or impractical to achieve through traditional manufacturing methods.

For many applications, WAAM can be used in conjunction with casting and forging as a form of hybrid manufacturing. It can also complement with feature additions to casting and forging projects, offering a faster and more adaptable route to production.

What materials can be used in WAAM?

A wide range of metals can be processed using Wire Arc Additive Manufacturing.

At DEEP Manufacturing, commonly used materials include carbon steels, stainless steels, Inconel 625, and nickel aluminium bronze. Our in-house metallurgy team continually tests and qualifies additional materials based on customer and application requirements.

What size of component can be created using WAAM?

The size of a WAAM-produced component depends on the system configuration.

At DEEP Manufacturing, single-arm WAAM systems can produce components up to 2.8m (9.2ft) in diameter and 3.2m (10.5ft) in height. Our Hexbot multi-arm WAAM system enables the production of components up to 6.2m (20.3ft) in diameter and 3.2m (10.5ft) in height, supporting some of the largest WAAM builds currently in operation.

What is DED-Arc manufacturing?

DED-Arc (Directed Energy Deposition – Arc) is the technical classification for Wire Arc Additive Manufacturing.

In practice, DED-Arc and WAAM refer to the same metal additive manufacturing process, with WAAM being the more commonly used industry term.

What are the limitations of WAAM?

Wire Arc Additive Manufacturing is a near-net-shape manufacturing process, meaning components are produced close to their final geometry rather than to finished dimensions. As a result, WAAM parts typically require post-processing, such as machining, to achieve final surface finish and tight dimensional tolerances.

This is standard practice for large-scale metal components, but it means WAAM is not intended to replace precision machining or high-volume production processes. It is also less suited to very small components or applications requiring high levels of repetition.

For the right applications, however, WAAM offers a robust and scalable alternative to casting and forging.

How fast can you produce a part using WAAM?

Because WAAM is an additive process, production speed is closely linked to the mass of the component being manufactured. Rather than measuring time per part alone, WAAM productivity is typically estimated using two related metrics: deposition rate and production rate.

Together, these metrics help predict how long it will take to manufacture a component and provide a more realistic view of delivery timelines for large, low-volume parts.

What is the difference between deposition rate and production rate?

Deposition rate refers to how quickly material can be laid down during welding. It represents the theoretical maximum rate at which metal wire can be deposited, based purely on process parameters.

Production rate, by contrast, reflects real-world manufacturing conditions. It accounts for all additional time required during production, including cooling between layers, surface preparation, inspection and scanning, torch cleaning, and system recalibration.

As a result, production rate is typically lower than deposition rate but provides a more accurate indicator of total manufacturing time, as it is influenced by part size, geometry, and quality requirements.

At DEEP Manufacturing, carbon steel deposition rates typically range from 2 kg to 8 kg per hour, with production rates averaging around 50% of the deposition rate, depending on component complexity and process requirements.

WAAM at DEEP Manufacturing

At DEEP Manufacturing, WAAM is delivered as part of a fully integrated manufacturing route, combining additive deposition with machining, welding, testing and certification. This approach enables the production of large, high-integrity metal components at speed, while meeting the quality and assurance requirements of safety-critical applications.