Advantages of WAAM for aerospace manufacturing
WAAM can provide several benefits within the production of large-scale metal components when compared to traditional casting and forging, including:
- Vastly reduced lead times for low-volume production
- Less material waste and improved buy-to-fly ratio
- Reduced tooling requirements for large, complex structures
- Versatility throughout the design and production process
DEEP Manufacturing WAAM capability
DEEP Manufacturing delivers end-to-end WAAM solutions for aerospace, from design optimisation to final production. Combining large-scale robotic systems with engineering and metallurgical expertise, we can produce high-integrity, low-volume components at speed.
With multi-arm capability and integrated hybrid manufacturing, DEEP Manufacturing supports complex aerospace parts while reducing lead times and supply chain risk.
Engineering expertise for high-integrity components
DEEP Manufacturing applies a structured engineering approach to deliver aerospace components with consistent quality and performance. Each step is controlled to meet demanding application requirements.
• Design for Additive Manufacturing (DfAM)
• Process development and parameter control
• Precision WAAM production
• Inspection, testing and compliance verification
Aerospace materials suitable for WAAM
WAAM supports a range of aerospace-grade materials, enabling the production of high-performance components with excellent strength-to-weight ratios. Materials such as stainless steels, titanium and aluminium offer corrosion resistance and fatigue durability.
Near-net-shape manufacturing improves material efficiency and reduces buy-to-fly ratios.
Quality standards and testing
DEEP Manufacturing operates in line with recognised quality standards and additive manufacturing best practices, supported by rigorous inspection and testing procedures in accordance with the relevant ASTM/ISO standards.
Aerospace sectors supported by WAAM
WAAM enables the production of large, high-performance metal components across multiple aerospace sectors, supporting faster delivery, design flexibility and improved material efficiency.
Large-format additive manufacturing supports engine components such as casings, inlet rings and structural housings. High deposition rates enable efficient production of complex geometries while reducing material waste.
In commercial aircraft programmes, additive manufacturing enables structural components, brackets and support structures with optimised geometries. This supports weight reduction, improved efficiency and faster production for low-volume or replacement parts.
For defence applications, the process enables rapid production of mission-critical components, including structural housings, enclosures and repair parts. It supports more resilient supply chains and faster response for secure, localised manufacturing.
Large-scale metal additive manufacturing supports components for launch systems, including tanks, structural sections and support assemblies. Complex geometries and improved material efficiency contribute to weight reduction and performance in space environments.
Additive manufacturing enables the production of large tooling, fixtures and jigs used in aerospace manufacturing. This supports faster turnaround of bespoke tooling, reduced lead times and greater flexibility for evolving production requirements.
Defence sector example components
Production of HPT cases, combustion cases and LPT cases using large-scale additive manufacturing. Enables near-net-shape structures, reducing machining requirements and improving efficiency when working with high-value aerospace materials.
WAAM enables the production of large rotating components for aerospace engines and transmission systems, delivering complex geometries, improved material efficiency and reduced lead times for critical engine applications.
Production of structural landing gear components using high-strength materials, supporting durability and performance under load. WAAM enables optimised geometries and efficient material use for low-volume or bespoke parts.
Additive manufacturing of tooling, fixtures and jigs used in aerospace production. Enables rapid turnaround of large, bespoke tooling while reducing cost, lead time and dependency on traditional manufacturing methods.