07.16.2026
Around 150 specialists from industry, research and engineering gathered in Berlin on June 11 for WAAMathon #3 to discuss the current state of Wire Arc Additive Manufacturing (WAAM). One message became clear throughout the event: in many industrial sectors, WAAM has progressed well beyond the demonstration stage. Consequently, discussions focused less on technical feasibility and more on how the technology can be qualified, standardized and integrated into industrial value chains in a reproducible manner.
Qualification Remains the Main Bottleneck
Carl Hauser of ASTM International/Wohlers Associates identified differing qualification approaches, limited comparability between applications and inconsistent data structures as key barriers to the industrial scale-up of WAAM. Carl Fruth of FIT AG likewise argued that the adoption of additive manufacturing is often constrained less by technical limitations than by a lack of confidence and acceptance within organizations.
Several presentations also demonstrated that industrial repeatability begins with the feedstock itself. Using titanium wire as an example, Tipro illustrated how wire quality directly influences process stability and the resulting component properties.
According to the speakers, the future growth of WAAM will depend not only on the performance of individual machines, but increasingly on the ability to qualify processes, materials and inspection methods in a transparent and reproducible way.
Beyond Trial and Error: The Digitalization of Melt Pool Control
Another major theme throughout the conference was the digital transformation of process development. Multiple presentations showed how artificial intelligence, simulation and data-driven modelling can replace the traditional trial-and-error approach that has long characterized WAAM process development.
Until only a few years ago, developing new WAAM processes relied heavily on engineering experience and extensive experimental campaigns. The approaches presented at WAAMathon demonstrated how this methodology is changing. AI-assisted
models, simulation tools and digital decision-support systems are expected to accelerate process parameter development, predict defects at an early stage and improve the transferability of process knowledge.
Companies including 3D Components and Aibuild presented solutions that combine artificial intelligence with thermo-mechanical simulation to identify suitable process parameters significantly faster than conventional methods. Siemens introduced agentic
systems and generative AI for automated process planning, while researchers from Technische Hochschule Brandenburg and Sweden’s University West demonstrated real-time melt pool monitoring based on sensor fusion, thermography and machine
vision.
Although the individual approaches differ, they pursue the same objective: transforming process knowledge into digital, structured information that can be systematically reused across industrial applications.
WAAM Is Moving Beyond Its Traditional Markets
The conference also demonstrated how rapidly the range of industrial applications has expanded in recent years. Examples presented during WAAMathon covered aerospace, energy, rail transportation, construction and maritime engineering. Notably, many projects were no longer focused on demonstrating technical feasibility but on solving concrete industrial manufacturing challenges.
Alloy Additive presented titanium components for space applications, while Guaranteed showcased additively manufactured grid fins featuring highly complex geometries for rocket systems. Siemens Energy and GEFERTEC demonstrated pathways towards serial production of highly loaded steam turbine blades. SNCF Voyageurs reported on the Additive4Rail project, which is qualifying WAAM for the long-term supply of spare parts in the railway sector.
Further presentations addressed material efficiency and sustainability in construction, as well as a European research project developing architecturally complex structural nodes for cruise ships. Together, these examples illustrated that WAAM is increasingly being considered for applications far beyond its traditional role in metal additive manufacturing.
From Manufacturing Process to Industrial System
Beyond the individual technical topics, WAAMathon #3 highlighted another important trend: discussions are increasingly shifting away from the manufacturing process itself towards the broader industrial ecosystem required for large-scale implementation.
Where earlier technology development focused primarily on deposition rates, materials and process stability, many presentations addressed data management, simulation, feedstock quality, qualification and standardization. The focus is therefore moving from
individual machines to the complete manufacturing chain.
Whether discussing automated parameter generation, digital process monitoring, qualification strategies for railway spare parts or the production of safety-critical components for the energy and aerospace sectors, the presentations consistently underlined one point: industrial adoption increasingly depends on the successful interaction of multiple disciplines.
WAAM is therefore evolving from a standalone manufacturing technology into an industrial production system in which material suppliers, software developers, machine manufacturers, end users and standards organizations must work closely together.
Standardization as a Shared Responsibility
These topics also formed the basis of the closing 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 agreed that harmonised standards and robust qualification procedures will be essential for broader industrial adoption.
Several speakers emphasized that companies—particularly in regulated and safety-critical industries—require reliable qualification evidence before additive manufacturing technologies can be introduced into serial production.
At the same time, the discussion highlighted that existing standards are not always keeping pace with the rapid development of the technology. Standardization therefore remains a collective task that requires active participation from end users, technology providers, research organizations and standards bodies alike. Panel members also encouraged participants to become actively involved in the relevant standardization working groups.
From Process Development to System-Level Integration
Taken as a whole, the presentations at WAAMathon #3 portrayed a technology that has already demonstrated its industrial viability across a wide range of applications.
The discussion surrounding WAAM is therefore evolving. The key question is no longer whether the technology works, but how it can be deployed reliably, economically and across a broad spectrum of industrial production environments.
The event was supported by industry sponsors, including GEFERTEC, a manufacturer of complete production systems for Wire Arc Additive Manufacturing (WAAM) of metal components.
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