Why Wire Arc Additive Manufacturing (WAAM)?
Additive manufacturing opens up new possibilities for producing complex metal components while using material efficiently. FatDED aims to distinguish between process-induced imperfections that can be tolerated and those that affect component performance and therefore become defects. The goal is to enable zero-defect components with allowable imperfections for fatigue-critical applications.
For its demonstrator components, FatDED uses Wire Arc Additive Manufacturing (WAAM), also known as DED-Arc. The process uses an electric arc to melt wire feedstock and deposit the material layer by layer.
Fast deposition rates and extensive build volumes make the process particularly suited for heavy-duty structural components. Compared to powder-bed systems, increased layer thickness enables significantly accelerated throughput and generous component dimensions. WAAM produces near-net-shape parts, combining industrial-scale additive manufacturing with efficient material use.
At the same time, process- and surface-related imperfections can influence fatigue performance. Understanding which of these imperfections are critical—and which are tolerable—is at the heart of FatDED.