Case studies
WAAM as a service

The startup costs for creating an additive manufactured part are relatively low. However, acquiring the equipment and knowledge needed for WAAM might lead to unnecessary risks, especially if a positive business case cannot be found. To explore whether WAAM is a valuable addition without taking these risks, a case study at the RAMLAB facilities can be done. If you are interested in doing a case study, get in contact. If you would like to know whether your project is suitable for WAAM, robotic welding or robotic repair, then request an assessment
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    Applications

    Two different types of case studies can be done in cooperation with RAMLAB: A repair case study and a WAAM case study.

    Repair case study

    In a Repair case study RAMLAB’s technology is used for the repair of a metal part of choice. RAMLAB offers an integrated method for repairing and regeneration of forging dies and molds consisting out of the 3D scanning of the damaged part, robotic welding system and additive toolpath generation software and tailor-made consumables.

    Benefits:
    • Increased productivity
      Automate repair activities that significantly increase the lifespan of your equipment.
    • Reduced human interaction
      Less exposure of workers to unhealthy conditions
    • Reduced material costs
      Less material needed due to near net shape repair and regeneration

    WAAM case study

    In a WAAM case study RAMLAB’s technology is used to print a metal part of choice up to 6 meters. The benefits of this include:

    • Reduced lead times
      For rapid production of custom parts, one-offs and functional prototypes
    • Reduced material costs
      Near net shape production of parts made out of exotic materials such as inconel.
    • Production of quality parts
      Exceptional quality parts compared to sand casting due to real time monitoring of the production process.
    Interested in doing a case study?
    Get in contact.

    Steps in a case study

    1. Part selection

    The first step in every WAAM process is the selection of the to-be manufactured part. This selection is based on the required specifications and the expected business case. At the start of the process also the choice is made whether certification of the selected part is required.

    2. (Re-)Design for CAD/CAM

    Based on design rules for WAAM a CAD model for a pre-form is made. This pre-form is a near net shape of the actual part that can be milled to final dimensions. The CAD model uploaded to the MaxQ Webapp.

    3. Material selection

    Based on the intended mechanical properties a selection for a material and wire feedstock is made. A number wire feedstocks have been evaluated in earlier projects. For the material selection we work closely together with welding thread producers Voestalpine and Lincoln Electric.

    4. Manufacturing

    Based on the digital model, choice of material and several tests, the MaxQ Webapp creates a toolpath for the welding robot to follow. This toolpath is uploaded to the robot and production is started at the RAMLAB premises.

    5. MaxQ

    During production RAMLAB’s MaxQ system is used to monitor and control the production. In this way the production quality data can be assessed and stored.

    6. Post processing

    Depending on the requirements, the part will be milled, heat treated and/or post processed in other ways.

    7. Quality testing

    Both non-destructive and destructive tests can be executed, depending on the requirements defined in step one.

    8. Documentation

    Throughout the whole WAAM process all choices, tests and other information are documented in detail. This information is gathered and presented in written form.

    9. Decision

    During the evaluation the business case is (in)validated, and the decision for proceeding in buying a WAAM cell with MaxQ is made.

    Interested in doing a case study?
    Get in contact.