The new Wire Arc Additive Manufacturing (WAAM)-based Additive Cell from Fronius (Portage, IN) combines state-of-the-art CMT welding technology, intelligent process control, and user-friendly software to produce high-quality metal components.
A stable welding process that enables uniform layer build-up is crucial for achieving the desired quality with the Directed Energy Deposition-Arc (DED-Arc) method. The CMT Additive PRO, which is based on the Cold Metal Transfer (CMT) process developed by Fronius, is particularly well-suited to additive manufacturing as a relatively cool dip transfer arc process that combines a higher deposition rate than other additive manufacturing methods with low heat input. The “CMT Additive PRO” welding characteristics are specifically tailored to the requirements of additive manufacturing, providing features such as a deposition rate stabilizer, Pulsed HotStart, CTWD measurement, and power correction to ensure the necessary process stability.
The Fronius Additive Cell includes not only the hardware but also the company’s proprietary software bundle Vectris, which brings together the machine tool service kit (MTSK) and the post-processor on a single central platform. Developed by a highly experienced team of Fronius specialists, the software is designed specifically for additive manufacturing with the Fronius Additive Cell. In addition to an integrated kinematic model, an adapted user interface, and validated welding operations for additive processes, it also supports geometry-based detection of different component regions. This allows for flexible process parameters, such as different settings for outer walls, panels, infills, or component joints. Thanks to the “FroArc” welding command integrated into the post-processor, these so-called “build styles” are translated directly into code for the welding robot, and the system switches to the correct welding parameters at the exact desired location.
More information: www.fronius.com