On-demand manufacturing for supply chain resilience
At DEEP Manufacturing, we design and re-engineer components for Wire Arc Additive Manufacturing (WAAM) or hybrid production using the Directed Energy Deposition (DED) process. With multi-robot systems capable of producing parts up to 6.2m (20.3ft) in diameter and 3.2m (10.5ft) in height, and hybrid manufacturing capabilities in both the UK and US, we support global energy projects requiring large, high-integrity metal components.
The benefits of WAAM for the energy sector
Wire Arc Additive Manufacturing (WAAM) enables the production of large-scale metal structures faster and with greater supply chain flexibility than traditional manufacturing methods.
- Reduced lead times through near-net-shape production
- Elimination of complex tooling and mould requirements
- Greater supply chain flexibility and localisation
- Lower material waste compared to traditional methods
- Efficient production of large, low-volume components
How we deliver and qualify WAAM parts
We can design for WAAM (DfAM) and take your product through production, post-processing and testing using in-depth process and part qualification.
Process qualification: Establishing the influence of parameters such as heat input, bead strategy, interpass temperature and wall thickness.
Part qualification: Focusing on the specific component geometry, local thermal history and any feature-driven effects on material properties and integrity. Across both stages, extensive mechanical testing and NDT are usually carried out to verify compliance with product requirements and applicable AM standards.
Advanced materials for industrial additive manufacturing
DEEP Manufacturing works with advanced alloys suited to demanding energy environments. Our WAAM processes currently support carbon steels, Inconel 625 and Nickel Aluminium Bronze (NAB) for high-strength, corrosion-resistant industrial components, with new materials regularly tested by our in-house metallurgy team.
Capabilities
Large-scale, low-volume WAAM and hybrid manufacturing for high-integrity energy components. We are the only DED-Arc provider globally with Approval of Manufacture for steel pressure hulls, hull structures and equipment, and pressure vessels for human occupancy (PVHOs).
Energy sector areas of application
Wire Arc Additive Manufacturing supports the rapid production and in-service repair of large-scale metal components used across energy infrastructure. From rapid prototyping to full-scale production, near-net shape structures and critical spares, WAAM can help reduce lead times, improve supply chain resilience and support maintenance of essential assets.
Manufacture of large structural components, tooling and replacement parts for wind turbine systems, supporting faster deployment and reduced downtime across onshore and offshore wind installations.
Production and refurbishment of large metallic components such as turbine housings, structural elements and hydraulic system parts used in hydroelectric power generation.
Manufacturing and repair of high-integrity metal components where traceability, inspection and strict quality control are essential for safe nuclear power operations.
Manufacture of pressure vessels, storage structures and infrastructure components supporting hydrogen production, storage and transport.
Production of complex structural components, prototypes and low-volume parts used across emerging renewable energy technologies and infrastructure, for example transmission casings.
Fabrication and repair of large subsea and offshore components including manifolds, valve bodies, pump housings, pressure vessels and structural equipment used in oil and gas production.
Energy sector example components
Pressure-rated connection components used to join pipes, valves, pumps and other equipment in high-pressure piping systems.
Large structural and pressure-containing components used in offshore drilling systems to control well pressure and prevent uncontrolled hydrocarbon release.
Structural housings that contain the internal components of industrial pumps used in subsea systems, refineries and power generation facilities.
Connectors, hubs and structural joining elements used in subsea and surface pipeline systems for the transport of oil, gas and other energy resources.
Flow-control components used throughout energy infrastructure to regulate, isolate or direct the movement of fluids and gases.