Siemens High-Tech Solutions for Wire Arc Additive Manufacturing (WAAM)

Even more innovation in new technological territory! Until now, powder-based processes have dominated the additive manufacturing scene. This could be about to change, because Wire Arc Additive Manufacturing (WAAM) offers advantages such as high buildup rates, cost-efficient machinery, the ability to add new material on existing parts, and almost unlimited component dimensions. In addition, wire is more easily and safely handled than powder. Now, with the latest high-tech solutions from Siemens that ensure precise, simple, and economical process control, WAAM is ready to take additive manufacturing to a new level.

Many manufacturing companies still view additive manufacturing (AM) with a wait-and-see attitude. I’m a great believer in this alternative manufacturing technology. Up until recently, it was merely considered as a process for low volume production applications (aerospace, medical technology, etc.), but AM is now making its way into mass production.

Now, disruptive companies are already one step ahead and are looking at alternative solutions to the classic powder-based process. Additive manufacturing with an electric arc is a leading candidate, interesting for its superior cost-effectiveness, speed and ease of handling. Wire Arc Additive Manufacturing uses conventional standard soldering equipment, where component manufacturing is carried out with direct metal deposition of solder. Advantages: high buildup rates and almost unlimited component sizes.

Engineering workflow completely covered

Siemens supports product manufacturers and machine builders in all process steps, enabling seamless mapping of the digital additive manufacturing chain. At the product design stage, Siemens NX simplifies optimization by providing easy sketching functions. The design features optimized in NX, and the resulting model changes, are completely transferred to the subsequent manufacturing process, simplifying the creation of tool paths. Manufacturing can then be visualized using the CAM multi-axis machine simulation, to help deal with any problems such as collisions.

To these advantages, Siemens now adds enhanced robot control with superior accuracy using SINUMERIK Run MyRobot /Direct Control. Compared to the typical robot accuracy of 0.7 mm to 2 mm, the precision is now increased to 0.1 mm to 0.7 mm. It’s achieved through CNC integration with complex algorithms, a special calibration solution, a new compile cycle, and a second encoder. This allows us to help users create precise, efficient robot cells by directly controlling the robot unit. Direct control also means customers can control the machine using ordinary CNC skills, without needing special know-how for programming robot controllers. They can also take advantage of pre-configured data sets that simplify commissioning. By integrating the digital twin of the robot into the CAD/CAM system based on SIEMENS NX using the SINUMERIK post-processor and machine simulation, the entire engineering workflow is covered.

A perfect match – digital twin combined with real manufacturing process

To run the application using a robot, SINUMERIK Run MyRobot /Direct Control establishes direct control of the robot unit. The SINUMERIK controller can also be used to integrate sensors for measuring important process parameters such as nozzle position, temperature distribution, layer thickness, wire-feed speed, and the shape of the melt pool.

Another tool in the suite, SINUMERIK Edge, delivers a cutting-edge quality assurance system for advanced data analytics. SINUMERIK Edge merges the data from independently acting sensors, reliably detects anomalies in the sensor values, and enables remote access to the machine unit.

Taking it to the next level The bottom line is that as manufacturers seek to unleash the greater throughput and flexibility that are possible with WAAM, Siemens NX CAD/CAM, SINUMERIK Run MyRobot /Direct Control, and SINUMERIK Edge enable new levels of precision, efficiency, and cost-effectiveness, while simplifying use and mapping the entire process in a consistent digital chain for an optimal workflow.