Additive Manufacturing

Large-Scale Additive Manufacturing


The demand for large-scale additive manufacturing (LSAM) is rapidly growing, as this process allows large products and parts to be produced more quickly and efficiently. Different from 3D printing, this type of product manufacturing produces industrial, large-scale components. Newer to mainstream manufacturing, large-scale additive manufacturing builds products and components faster and more efficiently than ever before.

There are three types of large-scale additive manufacturing:

  1. Direct energy deposition additive manufacturing
  2. Ultrasonic additive manufacturing
  3. Friction stir additive manufacturing

Direct Energy Deposition Additive Manufacturing

In directed energy deposition , thermal energy is used to either 1) add or fuse an item onto an existing part, 2) make a new part, or 3) make a repair. The components are built on layer by layer from a nozzle starting from the base of a component. There are three types of direct energy deposition : laser, arc, and electron beam.

Currently, direct energy deposition has a number of advantages for large builds, including productivity and time efficiency. It also allows you to control the grain with various types of metals, which makes it easier to repair or add to large-scale parts.

Ultrasonic Additive Manufacturing

This low-temperature type of large-scale additive manufacturing allows for the joining of dissimilar metals. As a hybrid type of technology, ultrasonic additive manufacturing creates large-scale structures while controlling cost and quality.

There are many positive aspects of ultrasonic additive manufacturing, but one of the most recent and exciting is letting companies think big: Instead of designing for separate parts, additive manufacturing allows companies to build items as one part without any limitations on size, shape, or material.

Friction Stir Additive Manufacturing

EWI often recommends friction stir welding to address the challenges that come with producing large, complex components from items that are not fusion weldable materials. Not an inherently additive process, friction stir welding is a new type of sheet lamination process that uses friction stir technology for large-scale additive manufacturing.

How EWI Handles Large-Scale Additive Manufacturing

EWI is at the forefront of large-scale additive manufacturing development. Are you looking to improve your LSAM technology? Our team can help identify the best options, develop the right solution, and implement the new process in your workflow. Talk to an expert at 614.688.5000 or fill out a contact form to get started.