Held recently in Frankfurt, Formnext 2024 featured some eye-catching advances in the field of Large Format Additive Manufacturing. Innovation and world premieres were at the heart of the event, with 864 exhibitors presenting their latest products and technologies. A key highlight was Caracol’s introduction of Vipra AM, a revolutionary technology that transforms the production of large-scale metal parts.
Also read: Caracol launches Vipra AM
Vipra AM: A Game-Changer in Large Scale Metal Production
In an exciting development for Large Format Additive Manufacturing (LFAM), Caracol introduced Vipra AM, a new robotic platform designed to change how large-format metal components are made. Vipra AM is a robotic large-scale Direct Energy Deposition (DED) platform that leverages wire arc additive manufacturing processes. This technology is seamlessly developed into a hardware, software, and automation proprietary turnkey system.
Key Features of Vipra AM Technology: Flexibility and Precision
The platform was designed to maximize flexibility, control, and performance, expanding the possibilities of Large Format Additive Manufacturing to a broader range of applications. Caracol’s mission is to enable global manufacturing companies to produce advanced large-scale industrial parts both efficiently and sustainably.
At Caracol, they have spent years developing the Vipra AM platform with a strong application-first approach. This extensive work led to the creation of two new configurations of Vipra:
- Vipra XQ (Extreme Quality): This configuration utilises Plasma Arc Deposition technology to produce high-quality, precise components. It is best suited for applications requiring superior strength and precision. Vipra XQ can process a wide range of metals, including stainless steels and titanium alloys. Its applications are ideal for industries like aerospace (load-bearing brackets, structural components) and energy (valves, gauges, structural piping connectors).
- Vipra XP (Extreme Productivity): Focused on maximizing productivity and minimizing operating costs, Vipra XP is ideal for industries that require lightweight, large-scale metal parts. It can print aluminum and nickel-based materials and is perfect for applications like automotive components, aerospace pressure vessels, and marine propellers.
Benefits of Vipra AM for Complex Large-Scale Metal Projects
Vipra AM was built to produce advanced applications, such as load-bearing finished parts, lightweight structures, high-temperature molds, cladding, and on-demand spare parts. With its innovative design and cutting-edge technology, Vipra AM is a major step forward in Large Format Additive Manufacturing, making it easier for manufacturers to meet complex industrial demands.
Enhancing Productivity and Reducing Production Costs with Vipra AM
"The launch of Vipra AM represents a breakthrough in the metal additive manufacturing industry," says Gianrocco Marinelli, Metal Additive Manufacturing Director at Caracol. Vipra AM introduces capabilities that complement existing processes, enabling hybrid production models that combine legacy techniques with advanced metal deposition. This helps manufacturers optimize their production lines, reduce waste, speed up lead times, and drive overall efficiency.
Renishaw's New Dual Laser Metal 3D Printer at Formnext 2024
Meanwhile, the UK-based company Renishaw launched the RenAM 500D, a new dual laser variant of its metal additive manufacturing machine. This machine offers exceptional flexibility, productivity, and cost-efficiency for a wide range of budgets, lowering the entry barrier to high-productivity metal additive manufacturing.
The dual laser system increases throughput and reduces production times compared to single-laser systems, helping companies reduce costs per part. The RenAM 500D Ultra model, fitted with Renishaw’s TEMPUS™ technology, allows the laser to fire while the recoater is moving, cutting production time by up to nine seconds per build layer. This system boosts production speed and reduces costs while maintaining the high-quality standards expected in metal additive manufacturing.
WAAM3D's New RoboWAAM XP System: A New Milestone in Additive Manufacturing
WAAM3D also unveiled its new large format RoboWAAM XP system at Formnext 2024, featuring Cranfield University’s patented Cold-Wire Gas Metal Arc (CWGMA) process. This process enables superior deposition rates of up to 15 kilograms per hour while maintaining the necessary precision for high-performance materials. The RoboWAAM XP is designed to manufacture large-scale spare parts with short lead times.
With its 2 x 2 x 2 meters build envelope and a maximum payload of 2.1 tonnes, the RoboWAAM XP system provides manufacturers with higher productivity and precision. The system supports a variety of materials, including iron, aluminum, nickel, and copper, and offers enhanced control for a broad range of industrial applications.
How Caracol, Renishaw, and WAAM3D are Shaping the Future of Large Format Additive Manufacturing
Each of these advancements—from Caracol’s Vipra AM system to Renishaw's dual-laser metal 3D printer and WAAM3D's RoboWAAM XP—represents a step forward for Large Format Additive Manufacturing and its application in industrial sectors like aerospace, automotive, and energy. By adopting cutting-edge technologies and innovative manufacturing approaches, these companies are making it possible to produce high-quality, large-scale metal parts more efficiently than ever before.
The integration of these advanced systems into manufacturing processes not only reduces material waste and accelerates lead times but also helps manufacturers stay competitive in a rapidly evolving market. As the possibilities for Large Format Additive Manufacturing continue to grow, the industry is poised to achieve even greater levels of innovation and efficiency.
Conclusion: The Impact of Large Format Additive Manufacturing on Industry
The future of manufacturing lies in Large Format Additive Manufacturing. With the continued development of platforms like Vipra AM, the RenAM 500D, and RoboWAAM XP, manufacturers can expect enhanced productivity, lower costs, and higher-quality outputs. As the industry evolves, the use of advanced additive manufacturing technologies will continue to revolutionize how large-scale metal parts are produced across multiple sectors.
