Lincoln Electric expanded into large-format metal additive manufacturing with its Wire-Arc Additive Manufacturing (WAAM) systems, designed and produced by Lincoln Electric Additive Solutions. The setup features company-built power sources, wire feedstock and Sculpt Print OS path-planning software, with the robot arm sourced externally, enabling prints roughly the size of an eight-foot cube and larger when segmented and joined.
Their vertically integrated pipeline ties Baker Industries’ machining and post-processing in Macomb, Michigan, to Lincoln’s Cleveland AM hub, with 26 robotic WAAM cells running 24/7. The systems handle heavy parts up to 20,000 lbs and print alloys including mild steel, high-strength low-alloy steel, multiple stainless and nickel alloys, iron-nickel 36 and copper-nickel 70/30.
For industries stalled by long casting and forging lead times, Lincoln’s WAAM approach shortens supply chains and enables on-demand production of large structural components. Certified to ISO 9001 and AS9100 and holding defense approvals, the offering targets repairs and replacements at casting scale where speed and material control matter most.
Image Credit: Carlos Jones/ORNL, U.S. Dept. of Energy
What's Driving This Trend
- Large-scale WAAM Adoption
- Rapid scaling of WAAM systems enables on-demand production of multi-ton metal structures previously constrained by casting and forging lead times.
- Vertically Integrated AM Supply Chains
- A shift toward in-house power sources, feedstock control and partnered machining creates tight quality and lead-time management across the AM value chain.
- Certified Multi-alloy AM Processes
- Available ISO 9001, AS9100 and defense approvals for stainless, nickel and specialty copper-nickel alloys opens pathways for AM to substitute certified castings in regulated applications.
Who This Affects Most
- Aerospace and Defense
- High-certification WAAM capabilities present opportunities for producing large, flight-critical structures and rapid field repairs that meet stringent quality standards.
- Heavy Equipment and Marine
- Production of 20,000-lb components and robust alloy options supports replacement and retrofitting of oversized parts typically requiring long lead-time castings.
- Energy and Infrastructure
- Segmented printing and joining of large structural elements enables localized, on-demand fabrication of infrastructure components for reduced logistical overhead.
