Wire Arc Additive Manufacturing (WAAM) is currently one of the most productive processes in additive metal manufacturing. Instead of metal powder, metal wire is deposited layer by layer using an electric arc. The process is particularly well-suited for large components and is gaining importance in sectors such as aerospace, the energy sector, and rail transportation. At the third WAAMathon in Berlin, it became clear that the discussion surrounding the technology is shifting noticeably: The focus is no longer on technical feasibility, but rather on how WAAM can be reliably and cost-effectively integrated into industrial production processes.

About 150 experts from industry and research gathered in Berlin on June 11, 2026, for the third WAAMathon, organized by the Berlin.Industrial.Group. (B.I.G.). The presentations and discussions made it clear that many companies are now making the transition from initial demonstrators to concrete industrial applications.

“The momentum in Berlin was palpable. We’re no longer discussing ‘if,’ but rather ‘how.’ The integration of AI-supported process planning with real-world industrial applications across a wide range of industries shows that the WAAM community has moved beyond the laboratory development phase,” said Stefanie Brickwede, Mobility Goes Additive (MGA)/Head of Additive Manufacturing at Deutsche Bahn.

The bottleneck today lies in training and standardization

While the focus in recent years has primarily been on process stability, materials, and build rates, companies are now paying greater attention to the qualification and standardization of their processes.

Carl Hauser of ASTM International/Wohlers Associates pointed to differing qualification approaches, a lack of comparability between applications, and inconsistent data structures as major hurdles to industrial scaling. Carl Fruth of FIT AG made it clear that the adoption of additive manufacturing often fails not so much due to technical limitations as to a lack of trust and acceptance within companies.

Several presentations also showed that reproducible manufacturing processes begin with the raw material itself. Using titanium wires as an example, Tipro demonstrated the impact of material quality on process stability and component properties. For industrial applications, therefore, it is not only high-performance equipment that matters, but also reproducible materials, validated processes, and traceable testing criteria.

“WAAM has the potential to produce high-quality titanium-based components for the aerospace industry with a shape close to the final contour. Compared to other DED processes, WAAM stands out with significantly higher deposition rates. At the same time, the quality of the wire as the raw material plays a crucial role,” explains Terry Huang, an engineer at the Tipro Group.

AI Is Expected to Accelerate Process Development

Another key focus of the conference was the digitization of process development. Just a few years ago, the development of new WAAM processes was often based on empirical knowledge and extensive test series. In the future, artificial intelligence, simulations, and data-driven models are expected to increasingly supplement or replace this trial-and-error approach.

3D Components and Aibuild presented approaches that use AI and thermomechanical simulations to more quickly determine suitable process parameters. Siemens showcased agent-based systems and generative AI for automated process planning. Researchers from Brandenburg University of Applied Sciences and Sweden’s University West demonstrated methods for real-time monitoring of the melt bath. Despite differing approaches, these developments share a common goal: to make process knowledge digitally available and easier to transfer to new applications.

From Prototype to Industrial Application

The application examples also demonstrated just how widely WAAM has become established. The spectrum ranged from aerospace and energy and rail technology to construction and maritime applications. The focus was primarily on specific industrial challenges rather than purely theoretical proof-of-concept studies.

The exhibition vividly demonstrated the complexity of components already produced using WAAM. Shown here is a mixed-drill head for tunnel construction, produced by GEFERTEC. In the background is a rocket nozzle mounted on a printed mandrel (Siemens/VLM Robotics). © B.I.G.

Alloy Additive reported on titanium components for aerospace applications. Guaranteed presented additively manufactured grid fins with complex geometries for rockets. Siemens Energy and GEFERTEC demonstrated the path to series production of high-load steam turbine blades. SNCF Voyageurs is working on the Additive4Rail project to qualify WAAM for the long-term supply of replacement parts in rail transport. These examples were complemented by presentations from the construction industry on material efficiency and sustainability, as well as from a European research project on architectural structures for cruise ships. Overall, the program made it clear that WAAM is now viewed as extending far beyond the traditional fields of application for additive metal manufacturing.

The focus is on the entire process chain

As industrial applications grow, the focus of development is also shifting. Many presentations no longer dealt exclusively with the actual manufacturing process, but rather with topics such as data management, simulation, material quality, qualification, and standardization. As a result, the focus is increasingly shifting to the entire process chain.

Whether it’s automated parameterization, digital process monitoring, the qualification of replacement parts, or the manufacture of safety-critical components for energy and aerospace applications—the industrial use of WAAM increasingly depends on the interaction of various disciplines. Material manufacturers, software providers, machine builders, users, and standardization organizations must work closely together to achieve this.

Uniform standards remain a key factor

This trend was also reflected in the concluding panel discussion, “Standardization and Certification: What Else Is Needed for Scaling Up?” Moderated by Stefanie Brickwede (Mobility Goes Additive/Deutsche Bahn), representatives from KSB, Qualified AM, Siemens Energy, and ASTM International/Wohlers Associates discussed the prerequisites for broader industrial adoption.

There was agreement that harmonized standards and robust qualification processes—particularly in regulated and safety-critical industries—are prerequisites for the use of additive manufacturing processes in mass production. At the same time, the participants pointed out that existing regulations often fail to keep pace with technological developments. Accordingly, the further development of standards is a joint task for industry, research, and standardization organizations.

“The WAAMathon has now become a regular gathering for the WAAM community. The conversations during the breaks were extremely focused. You can tell that everyone here is deeply immersed in the topic and has a very clear understanding of the challenges we must tackle together as a community when it comes to industrial scaling,” said Stefan Angel, Business Development Manager for Additive Manufacturing Germany at Siemens AG.

The conference made it clear that the challenges facing WAAM are shifting. Technical feasibility is no longer the primary focus in many fields of application today. Rather, the key factor will be how the process can be integrated into existing industrial production environments using standardized processes, robust qualification, and digital tools.