WAAM 3D Printing Service / WAAM Part Production

Whether you’re validating a new design, testing a process, bridging a production gap, or buying time until your system arrives, One Off Robotics delivers on-demand WAAM 3D printing services using our advanced Monarc platforms. Our wire arc additive manufacturing (WAAM) process produces certified-grade metal parts faster and at lower cost than casting or machining, making it ideal for aerospace, defense, energy, mining, and R&D applications.

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High-detail WAAM 3D printed metal auger integrated on shaft
Wire Arc Additive Manufacturing (WAAM) 3D printed metal boat propeller prototype
Infographic explaining what WAAM is: a welding torch deposits wire with shielding gas to create a melt pool, stacking metal beads layer by layer on a build plate in the wire arc additive manufacturing process.

What Is WAAM 3D Printing? Understanding Wire Arc Additive Manufacturing

WAAM, or Wire Arc Additive Manufacturing, is an advanced form of metal 3D printing that uses an electric arc welding torch to melt wire feedstock, depositing it layer by layer to create near net shape metal parts. This process enables the production of large, strong, fully dense, and durable components faster and at a fraction of the cost of traditional subtractive manufacturing methods. At One Off Robotics, we’ve enhanced WAAM with closed-loop thermal machine vision, a technology that continuously monitors the process in real time. By actively adjusting parameters during printing, our system maintains process stability and ensures consistent quality across even the most complex geometries. This combination of proven welding fundamentals and intelligent automation delivers reliable results for industries that demand high-performance metal parts.

On-Demand WAAM 3D Printing Services

Large WAAM 3D printed steel cone for defense munitions applications

We deliver certified-grade metal parts with Wire Arc Additive Manufacturing (WAAM) in a fraction of the time and cost of traditional casting or machining. Our on-demand service means you don’t need to own a machine. Simply send us your design, and we’ll produce large-scale metal components quickly and affordably.

We print WAAM parts every day on our Monarc system for aerospace manufacturers, defense contractors, mining OEMs, and R&D teams who need reliable, production-grade metal parts with speed and precision.

Available Materials For WAAM Process

  • ER316LSI

    Stainless Steel 316L

    Highly corrosion-resistant grade of austenitic stainless steel with great mechanical properties. Ideal for marine and chemical applications.

  • Mild Steel ER70S-6

    Mild Steel ER70S

    Also known as low alloy carbon steel or mild steel, this is a highly versatile material due to its strength, ductility, and low cost. ER70S is used in many applications, including construction, automotive and manufacturing.

  • ER CuNiAl

    NiBrAl

    This alloy is known for its high strength and excellent corrosion resistance. It's also used in castings, particularly for larger parts, due to its strength and ability to withstand corrosion.

  • Ti-6Al-4V

    Titanium 6-4

    High-strength Alpha+Beta alloy with excellent fracture toughness, corrosion resistance and biocompatibility. Widely used in aerospace, marine, chemical and biomedical industries.

  • ERNiCrMo-3

    Inconel 625

    Ni-based superalloy with excellent mechanical properties at a wide range of temperatures. It is an ideal choice for cladding or repair.

  • ERNiFeCr-2

    Inconel 718

    High-strength nickel-super alloy with a large working temperature range. Highly resistant to cracking while protecting well against corrosion.

  • Tool Steel H11

    Tool Steel H11

    A chromium-based steel alloy, it’s one of the most commonly used tool steels, thanks to its outstanding impact toughness.

  • Invar 36

    Invar 36

    This alloy gets its name thanks to its extremely low coefficient of thermal expansion, from -250 °C up to about 200 °C. it makes an ideal choice for measuring equipment and cryogenic applications.

  • Aluminum 5356

    Aluminum 5356

    Known for its high strength, good corrosion resistance, and excellent weldability, AL5356 is suitable for various applications, particularly in marine and automotive industries.

  • Other Materials

    Looking to print in a different material? One Off Robotics has you covered. Contact us for material availability and pricing.

Advantages / Benefits of Our WAAM Service

  • Produce oversized and complex metal components beyond the limits of traditional 3D printing.

  • Accelerate production with WAAM’s high deposition speed for rapid part turnaround.

  • WAAM achieves up to 95% material utilization, lowering costs compared to machining or casting alone.

  • Eliminate expensive dies and molds, shorten lead times with direct wire fed 3D printing.

  • Support low volume, custom metal part production without high setup costs.

  • WAAM parts provide superior fatigue resistance and mechanical performance for industrial use.

WAAM FAQ

  • WAAM 3D printing offers several advantages over casting, forging, or subtractive machining. It enables faster lead times by eliminating tooling, reduces material waste through near net shape deposition, and allows production of very large metal parts that would be impractical with traditional methods. WAAM also simplifies complex supply chains by enabling on demand manufacturing close to the point of use.

  • Our WAAM service supports a wide range of industrial metals including stainless steels, aluminum, titanium alloys, Inconel, and tool steels. This flexibility makes WAAM suitable for aerospace, defense, marine, and energy applications where certified-grade metals are required.

  • WAAM is uniquely capable of producing very large components thanks to its scalable robotic platform. Parts can range from small prototypes to multi-meter structures, with deposition rates up to several kilograms of metal per hour. This makes WAAM ideal for large format applications such as structural aerospace components, shipbuilding, and heavy industry.

  • WAAM parts are deposited to near-net shape with typical dimensional accuracy of a few millimeters, depending on the geometry and material. For final tolerances, parts are usually finished using CNC machining or grinding. This hybrid workflow delivers both the speed and scale of WAAM with the precision of traditional machining.

  • WAAM is already being adopted across aerospace, defense, marine, energy, and heavy equipment industries. It is particularly valuable for producing large structural parts, replacement components, and prototypes where speed, size, and material performance are critical.

  • The key question everyone wants a simple answer to and no one wants to hear “it depends”. We price our WAAM service based on part complexity, the material being printed, the runtime on the machine, and the number of parts being requested. All of the work to produce a part goes into slicing and producing the first part. Printing duplicates is much easer. Therefore the first one costs more and subsequent prints are less. If you buy one of our systems we will provide all of the gold standard print programs to you so you can have immediate return on investment and success with your own machine. WAAM is especially cost-effective for large parts and low-volume production runs. For accurate pricing, we provide project-specific quotes.

  • Requesting a quote is simple. Send us your CAD model or part drawings through our online quote form, and our engineering team will provide a custom estimate based on your material, size, and application requirements. If you need an NDA in place fist that is no problem. Simply send that to us first. Our on-demand WAAM service is designed to get you production-ready parts quickly.