WAAM3D, a leader in wire-based additive manufacturing technology, collaborated with HeadChannel to streamline and automate their complex 3D printing process. Through a bespoke software solution, WAAM3D enhanced efficiency and maximised the potential of their advanced Wire Arc Additive Manufacturing (WAAM) system, further solidifying their leadership in the metal additive manufacturing sector.
The Challenge
WAAM3D sought to optimise their sophisticated 3D printing process. While their proprietary Wire Arc Additive Manufacturing (WAAM) system had demonstrated immense potential in producing large-scale, high-quality metal parts, managing this complex process required constant monitoring and manual input.
The manual nature of data tracking, process optimisation, and machine management was limiting operational efficiency. They needed a tailored software solution that could streamline the entire workflow—from managing large-scale 3D printing operations to monitoring in real-time, automating data collection, and ensuring precision.
Why HeadChannel?
WAAM3D approached HeadChannel because of our proven expertise in developing highly specialised software for advanced manufacturing processes. Our collaborative approach, agile development framework, and deep understanding of industry-specific needs set us apart from other providers. WAAM3D required a trusted partner who could not only understand the intricacies of their cutting-edge technology but also build a bespoke solution to help them push boundaries.
Our Approach
HeadChannel began by conducting in-depth workshops with the WAAM3D team to fully understand the existing processes, operational challenges, and specific software needs. The goal was to create an end-to-end software platform that would automate key tasks, enable real-time monitoring, and support continuous improvement.
We employed agile methodologies to develop a scalable software solution that integrated with WAAM3D’s existing hardware and technology, providing the following key features:
Real-time Monitoring – A central dashboard allowed operators to monitor every phase of the 3D printing process, ensuring precise control over temperature, speed, and material flow.
Data Collection and Reporting – Automated data collection streamlined the production process, storing key metrics for analysis and quality assurance.
Automation of Repetitive Tasks – The software eliminated manual input for repetitive actions, reducing errors and freeing operators to focus on critical tasks.
Customised Alerts and Notifications – Real-time alerts informed operators of potential issues, enabling proactive maintenance and ensuring that downtime was minimised.
Scalability – The system was built with scalability in mind, allowing WAAM3D to expand their operations and easily add new machines as the business grows.
Testimonial
“Working with WAAM3D was an exciting and rewarding challenge. Their vision to revolutionise metal additive manufacturing aligned perfectly with our expertise in developing complex, industry-specific software solutions. From the outset, we collaborated closely to ensure our solution fully integrated with their advanced technology and met their operational needs. The result is a system that not only automates key aspects of their 3D printing process but also positions WAAM3D at the forefront of innovation in their field. We are proud to have contributed to their success and to be a part of their journey toward transforming the manufacturing industry.”
Richard Bundock
CTO, HeadChannel
The Outcome
Through our partnership, WAAM3D saw a significant improvement in their operational efficiency. With real-time data monitoring and automated processes in place, they were able to reduce manual input and human error. The software provided them with the ability to quickly respond to any process disruptions, minimising downtime and optimising overall production efficiency.
The streamlined process not only increased productivity but also enhanced the precision and quality of the metal parts produced, ensuring that WAAM3D maintained its leadership in the additive manufacturing space. WAAM3D now has a robust, scalable platform that supports future growth and positions them as pioneers in the industry.
About
WAAM3D is a global leader in Wire Arc Additive Manufacturing technology, offering cutting-edge solutions for producing large-scale, high-performance metal components. WAAM3D’s mission is to revolutionise the manufacturing industry by providing cost-effective, flexible, and scalable 3D printing technologies that meet the demands of modern industrial applications. Their innovative approach to additive manufacturing makes them pioneers in their field, driving advancements in aerospace, automotive, and other critical sectors.
