MetalWorm provides a robotic Wire Arc Additive Manufacturing (WAAM) platform that builds near‑net‑shape metal components layer‑by‑layer from wire feedstock, offering high deposition rates and support for alloys such as aluminum, stainless steel, and Inconel. Integrated software delivers real‑time monitoring, digital‑twin simulation, and automated tool‑path planning to ensure consistent quality and traceability, while also enabling repair and cladding of existing parts. The solution targets manufacturers of large‑scale metal parts in aerospace, oil & gas, maritime, automotive, and energy industries.
Funding
Funding not disclosed
Founders
Product
Problem
Conventional metal manufacturing methods such as forging, casting, and traditional welding require expensive tooling, generate high material waste, and are limited in design flexibility, leading to long lead times and elevated production costs for large or complex components.
Solution
MetalWorm offers a robotic Wire Arc Additive Manufacturing (WAAM) platform that builds metal parts layer‑by‑layer from continuously fed wire using an electric arc. The system combines high deposition rates with a wide range of feedstock alloys (e.g., aluminum, stainless steel, Inconel) to produce near‑net‑shape components quickly and cost‑effectively. Integrated software provides offline simulation, multi‑axis tool‑path planning, process calibration, and a digital‑twin environment for end‑to‑end monitoring and traceability. Real‑time sensor fusion and machine‑vision control maintain melt‑pool stability, adjust heat input, and generate alerts, ensuring consistent mechanical quality. The solution also supports repair and cladding of existing parts, reducing downtime and extending component life.
Target Audience
Primary customers are manufacturers of large‑scale metal parts in aerospace, oil & gas, maritime, automotive, and energy sectors, as well as research institutions and universities seeking advanced additive‑manufacturing capabilities.
Features
- Robotic WAAM hardware with interchangeable ABB, Kuka, or Fanuc arms and external axis support (gantry, slider, positioner)
- High‑speed deposition using GMAW, GTAW, PAW, or WLAM processes for metals such as stainless steel, aluminum, Invar, and high‑temperature alloys
- Offline programme for process calibration, parameter libraries, and rapid tool‑path generation without expert knowledge
- Multi‑planar, non‑planar, B‑spline and conical tool‑path strategies with region‑specific planning
- Real‑time data acquisition (current, voltage, wire feed, gas flow, temperature, humidity, oxygen) with 3D melt‑pool visualization and HDR thermal imaging
- Digital twin simulation of robot kinematics and WAAM process for predictive quality and error detection
- Integrated CCTV, ERP/MES connectivity, and full event logging for traceability and compliance
- Cladding and repair module for fixing nicks, holes, and fractures on high‑value components