Fronius combines additive manufacturing, software and automation in a single package

With this latest innovation, Fronius is once again underscoring its position as a comprehensive solutions provider for additive manufacturing.

The expectations being placed on modern manufacturing processes are constantly increasing. Shorter development cycles, maximum material efficiency, and cost-effective production of complex geometries are in greater demand than ever before. From aerospace and automotive to pressure vessels, rolling stock, and oil and gas, many industries require customized, tailored solutions and spare parts that are available quickly: in other words, the exact areas where additive manufacturing can truly shine.

Compared to conventional manufacturing processes such as casting, cutting, or milling, additive components keep material consumption and costs low. "WAAM enables decentralised, location-independent manufacturing without the need for complex production lines. Even irregular geometries can be built to the highest quality standards without wasting valuable material," summarises Manuel Stinglmayr, Business Development at Fronius International.

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 stabiliser, Pulsed HotStart, CTWD measurement, and power correction to ensure the necessary process stability. "The CMT Additive PRO guarantees uniform and, above all, predictable layer build-up across the entire component. This drastically reduces scrap rates as well as the workload required for any rework," emphasises Manuel Stinglmayr.

Flexibility for custom welding solutions

For many companies, additive manufacturing presents numerous challenges. Compared to traditional manufacturing techniques, however, material waste is significantly lower, and neither complex molds and tools nor long lead times are required. Thanks in particular to the new Fronius Additive Cell, production of the first components can begin quickly.

The Fronius Additive Cell is a perfectly coordinated complete system developed by Fronius to meet the needs of industry. Inside the welding cell, the CMT Additive PRO and Fronius iWave ensure a precise welding process while the Polaris system remains in overall control.

"The Additive Cell combines proven welding technology, intelligent control, and Fronius's many years of welding expertise. Every component has been designed to complement the other, resulting in a stable manufacturing process," says Anna Dieplinger, Key Product Manager Additive Manufacturing, Automation & Digital Solutions at Fronius International.

The Fronius Additive Cell includes not only the hardware but also our 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 that 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 without delay. Fronius's integrated system, consisting of a welding machine and software, ensures a simple, stable, and reliable welding process.

360 degree service for additive manufacturing

The applications for the Fronius Additive Cell and WAAM in general are diverse, ranging from reverse engineering and optimisation of existing components to completely new designs. While reverse engineering is particularly useful for repairs when original parts are no longer available or the CAD data has been lost, designing new components permits optimised geometries. Both contribute to greater manufacturing efficiency and cost-effectiveness over the long term. To help customers with these requirements and more, Fronius offers a comprehensive package of consultation, feasibility studies, process development, and production services at our Prototyping and Manufacturing Center. We can also develop, test, and certify the optimal welding and pressure parameters for the respective welding materials. These ready-made and validated "recipes" can be licensed directly to you, allowing you to start production without delay. As part of our comprehensive 360 service offering, Fronius also handles the full process engineering for additive manufacturing projects upon request. Customers benefit from our expert knowledge, state-of-the-art development capabilities, and thoroughly tested solutions, all without having to take on any risk themselves.