Next step Gefertec innovation prints huge parts up to eight cubic meters in volume

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With its latest machine generation Arc80X, Gefertec offers even more possibilities for users of 3D metal printing of large components via Wire Arc Additive Manufacturing (WAAM).

According to Gefertec, the new machine generation Arc80X impresses with a larger build space, functions for automated manufacturing, and a module that allows the processing of titanium. Additionally, a comprehensive service package supports all those who do not have their own team of experts in the use of this type of additive manufacturing. 3D metal printing with WAAM is also being used for an increasing number of applications, as stated by Gefertec.

Larger build space and higher degree of automation

Gefertec relies on a CNC linear axis system for the machine kinematics, which ensures high precision for permanent process stability and repeatability reliability throughout the entire build space. In the 3-axis version, the new additive manufacturing system offers a build space of 2 × 2 × 2 meters and can generatively produce components with a total mass of up to 8 tons. The 5-axis version even prints components with a diameter of up to 0.9 meters and a height of up to 1.4 meters. Besides the larger build space of around 8 cubic meters, the new machine generation brings numerous other advantages. This includes a higher degree of automation, which improves efficiency in production while saving on personnel. Automated functions include integrated tool measurement, gas nozzle cleaning, wire cutting, and the exchange of wear parts.

Optional inert gas equipment allows for titanium 3D printing

Moreover, the new Gefertec machine generation impresses with an advanced process monitoring for ensuring component quality. The process monitor captures the necessary data and stores all relevant information during the printing process. According to the manufacturer, this allows for comprehensive documentation for quality assurance and process optimization. An integrated pyrometer measures the component temperature, which, along with active component cooling, contributes to a high quality of components. The optionally available protective gas box finally enables 3D printing in a closed protective gas atmosphere, allowing for the processing of challenging metals such as titanium.

Previous barriers to entry into WAAM can now be overcome

In the past, many potential users were deterred from the 3D printing process, mainly due to the necessary investments. Another main reason was often the lack of expertise within the company. However, Gefertec now also offers a comprehensive service package for this issue. Process technicians and CAM engineers from the 3D specialist support users in implementing component manufacturing on the Arc machines particularly easily. Services include, among other things, screening of components to check technical feasibility and identify efficiency potentials. Assistance is also provided with qualification processes. Thus, users can optimally use the Arc machines and enter into 3D printing via WAAM more easily – even without their own team of experts.

A complete manufacturing system with high build rates

Gefertec retains the advantages of the previous machine generations with the Arc80X series. Thus, the machine concept is a complete manufacturing system. Traditional metal inert gas welding is used for the additive manufacturing of components. The Arc machines then combine this with specialized CAM software and a Sinumerik control architecture, as Gefertec emphasizes. The process is known for high build rates and, since wire is used as the raw material, handling is easy and the material is relatively inexpensive. The machines are also already in intensive use in industrial applications – for example, in the energy sector for the series production of turbine components, as the manufacturer finally notes.