Fronius WAAM Additive Cell Combines Robot, Welder, and Software
Related To:
Nov. 2, 2026
3 min read
Spare parts, prototypes, and one-off metal components often mean long lead times, dedicated molds or tooling, and material lost to casting or milling. Fronius' Additive Cell is a complete wire arc additive manufacturing (WAAM) cell. It integrates a welding power source, robot, workpiece positioner, sensors, and build-planning software in one system. Shops can build complex metal parts with less material waste and no molds or tooling.
Applications
- Spare and replacement parts
- Prototyping
- Reverse engineering of existing parts
- Complex one-off metal components
Industries
- Aerospace
- Automotive
- Rail and rolling stock
- Oil and gas
Who It's For
- Replacing parts when originals or CAD data are gone
- Low-volume metal parts without molds or tooling
- Adding metal AM without building a production line
- Parts needing different settings for walls, infills, and joints
Features:
- Welding machines: iWave 500i AC/DC TIG and OPT/i Multiprocess PRO
- Welding packages: CMT, Pulse, Standard, PMC, and LSC
- Additive welding characteristics: CMT Additive PRO with deposition rate stabilizer, Pulsed HotStart, contact-tip-to-work distance (CTWD) measurement, and power correction
- Robot: ABB IRB 2600-20/1.65 with OmniCore controls
- Positioner options: ABB IRP A-500/1000 H700 for workpieces up to 1,102 lb (500 kg); ABB IRP A-750/1000 H700 for workpieces up to 1,653 lb (750 kg)
- System controls: Polaris with 21 in. (53 cm) multitouch display for managing all cell components
- Robot interface: RI FB Pro/i AM Basic and CFG/i RI FB PRO AM Basic
- Monitoring: ArcView3 visual monitoring and an interior camera for viewing the cell during operation
- Interpass temperature measured automatically by pyrometer and tactile sensor
- Service station with automated TCP measurement, contact tip changing (Robacta CTC), and torch cleaning (Robacta Reamer V Easy with wire cutter)
- Rotary tilting table clamping system with integrated continuous water cooling
- Vortex-tube torch cooling to shorten the cooling phase
- Vectris software bundle that combines the post-processor and machine tool service kit (MTSK) on one platform
- Integrated kinematic model and validated welding operations for additive processes
- Geometry-based detection of component regions, with separate parameters for outer walls, panels, infills, and joints
- FroArc welding command that turns these "build styles" into robot code and switches parameters at the set location
- Less material waste than casting, cutting, or milling, with no molds or tooling
Fronius
Portage, IN
(219) 734-5500
[email protected]
fronius.com
Contributors:
This piece was created with the help of generative AI tools and edited by our content team for clarity and accuracy.