The power of
Additive Manufacturing

Additive Manufacturing

In Additive Manufacturing (AM) or 3D printing, components are produced by applying material layer by layer. For the data preparation of the parts, a CAD software is needed. The components are printed using metal, polymer, ceramic, composites or hydrogels/bio inks as building material.

Additive layering methods

based on metal and plastic split up in

  • (Powder) bed systems

    e.g. Selective Laser Melting (SLM) or Selective Laser Sintering (SLS)

  • Arc manufacturing

    e.g. Wire Arc Additive Manufacturing (WAAM) or Wire Feed Laser Beam Melting

  • Nozzles-Systems
  • Laminating-Process

Benefits of AM

  • Freedom in design
  • Integration of functions
  • Lightweight construction
  • Reduced chip volume, tool wear and processing times compared to conventional manufacturing
  • Cost savings (for small batches)
  • Weight loss
  • Time savings (lead time reduction)
  • Highest component integration and performance
  • Individualization
Comparison

Conventional vs. Additive Manufacturing

The Technology

Wire Arc Additive Manufacturing (WAAM)

Wire Arc Additive Manufacturing (WAAM)

  • Layer-by-layer structure of the part using arc welding
  • Fusing of a metal wire with the aid of a welding torch forms the blank
  • Finishing of the fully built component by CNC-milling

Benefits

  • Robust process
  • Well-established and easy to handle
  • High building rate
  • Low residual stress in the component
  • Qualified processes ensure the highest quality

Advantages compared to other AM-technologies

  • Large building space
  • Easy material handling
  • Low efforts for post-processing
Patented Parallel Geometry

Multi-optional 6-axis machining center from METROM

The Mobile Smart Factory uses a hybrid machine from METROM for component production. Based on a patented parallel kinematics concept the machine combines Gefertec’s WAAM module with a milling and drilling unit.

The automated building with integrated finishing processes is based on CAD data of the component created in the operating container. With this solution, the system operator only has to set up and position the workpiece. The welding and machining process runs as an NC program based on pre-qualified parameters.

Operating principle

The main spindle of the machine is centrally positioned, allowing the machining of large workpieces.

The measuring of the workpiece, contour welding and milling are carried out consecutively in one clamping position. Subsequently an additional tool  can be used to smoothen out the roughness of the surface. All technological steps are realised by a direct tool change in the working area of the machine. Further possibilities like for example laser welding with wire or powder, screw extrusion additive manufacturing or plasma welding can be integrated later on, too.

Machine advantages at a glance

  • Low weight and low power input
  • Large building space with small installation area
  • High positioning accuracy and repeatability
  • Thermal compensation of the working envelope
  • Stiffness without foundation works
  • 3D-printing with integrated finishing

Find out more about METROM

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