Fraunhofer IAPT develops digital assistant system with mixed reality for robotic additive welding

XR Assistant for WAAM A Digital Assistant System for Robotic Wire Arc Additive Manufacturing (WAAM)

2025-11-12 Source: Fraunhofer IAPT | Translated by AI 2 min Reading Time

Taiwan Machine Tool & Accessory Builders' Association (TMBA)

SIMTOS (Seoul International Machine Tool Show)

Fraunhofer IAPT from Hamburg-Bergedorf, Germany has developed a digital assistant system with "mixed reality" glasses for robotic Wire Arc Additive Manufacturing (WAAM) in collaboration with partners and using machine learning.

The additive manufacturing process Wire Arc Additive Manufacturing (WAAM) offers several advantages compared to other 3D printing methods. However, it requires skill. A digital assistant system now provides relief by simplifying the setup of WAAM.(Image: IAPT) — The additive manufacturing process Wire Arc Additive Manufacturing (WAAM) offers several advantages compared to other 3D printing methods. However, it requires skill. A digital assistant system now provides relief by simplifying the setup of WAAM.
(Image: IAPT)

As part of the ITEA project Familiar, the Fraunhofer Institute for Additive Manufacturing Technologies IAPT has created a digital assistance system applicable via XR glasses for robot-assisted Wire Arc Additive Manufacturing (WAAM). According to further reports, the project partners have also established an architecture for Federated Machine Learning ("FedML") and analyzed it within use cases. In this additive manufacturing process, components are also produced layer by layer, but by melting metal wire using arc energy. However, this robot-assisted process has its challenges and requires significant expertise to ensure the quality of the components later or to avoid costly rework. The new assistance system now guides operators through the sensitive setup process using "Mixed Reality" glasses. Sensor data from an in-process stereo camera trains the "Machine Learning" model, which then calculates the parameters, as reported. The resulting digital system eliminates inefficient process steps, thereby halving preparation effort, as emphasized. Furthermore, the smart assistance system improves the quality of WAAM components.

Mechanically More Durable Components Through the WAAM Process

The advantages of WAAM include high speed and more efficient material usage, which are not available in other 3D printing processes. WAAM also creates large structures faster and more cost-effectively than the conventional powder bed process. Additionally, the components are characterized by high strength—offering better mechanical properties. The research results now enable the use of WAAM with minimal effort. Collaborative learning between edge devices and decentralized storage of information ensures data security and opens up the benefits of Machine Learning (ML) as well as virtual and augmented reality (VR and AR—combined referred to as XR = Mixed Reality) even to sensitive industries. Use cases from the automotive sector and additive manufacturing practice served to analyze and validate the approach, according to the team in Hamburg-Bergedorf, Germnay. The IAPT’s focus was on developing the system architecture in the 3D printing facility, integrating sensors, developing data flows and interfaces, as well as conducting evaluations and tests, the researchers report.

Subscribe to the newsletter now

Don't Miss out on Our Best Content

Business E-mail

Please enter a valid mailadress.

By clicking on „Subscribe to Newsletter“ I agree to the processing and use of my data according to the consent form (please expand for details) and accept the Terms of Use. For more information, please see our Privacy Policy. The consent declaration relates, among other things, to the sending of editorial newsletters by email and to data matching for marketing purposes with selected advertising partners (e.g., LinkedIn, Google, Meta)

Date: 08.12.2025

Naturally, we always handle your personal data responsibly. Any personal data we receive from you is processed in accordance with applicable data protection legislation. For detailed information please see our privacy policy.

Consent to the use of data for promotional purposes

I hereby consent to Vogel Communications Group GmbH & Co. KG, Max-Planck-Str. 7-9, 97082 Würzburg including any affiliated companies according to §§ 15 et seq. AktG (hereafter: Vogel Communications Group) using my e-mail address to send editorial newsletters. A list of all affiliated companies can be found here

Newsletter content may include all products and services of any companies mentioned above, including for example specialist journals and books, events and fairs as well as event-related products and services, print and digital media offers and services such as additional (editorial) newsletters, raffles, lead campaigns, market research both online and offline, specialist webportals and e-learning offers. In case my personal telephone number has also been collected, it may be used for offers of aforementioned products, for services of the companies mentioned above, and market research purposes.

Additionally, my consent also includes the processing of my email address and telephone number for data matching for marketing purposes with select advertising partners such as LinkedIn, Google, and Meta. For this, Vogel Communications Group may transmit said data in hashed form to the advertising partners who then use said data to determine whether I am also a member of the mentioned advertising partner portals. Vogel Communications Group uses this feature for the purposes of re-targeting (up-selling, cross-selling, and customer loyalty), generating so-called look-alike audiences for acquisition of new customers, and as basis for exclusion for on-going advertising campaigns. Further information can be found in section “data matching for marketing purposes”.

In case I access protected data on Internet portals of Vogel Communications Group including any affiliated companies according to §§ 15 et seq. AktG, I need to provide further data in order to register for the access to such content. In return for this free access to editorial content, my data may be used in accordance with this consent for the purposes stated here. This does not apply to data matching for marketing purposes.

Right of revocation

I understand that I can revoke my consent at will. My revocation does not change the lawfulness of data processing that was conducted based on my consent leading up to my revocation. One option to declare my revocation is to use the contact form found at https://contact.vogel.de. In case I no longer wish to receive certain newsletters, I have subscribed to, I can also click on the unsubscribe link included at the end of a newsletter. Further information regarding my right of revocation and the implementation of it as well as the consequences of my revocation can be found in the data protection declaration, section editorial newsletter.