After making a name for itself as a 3D printing service featuring large-format robotic arm extrusion 3D printers with custom-designed print heads, Italy-based Caracol AM launched its first large format polymer extrusion 3D printer, Heron AM, in 2022. This week it takes a bold new step into metal 3D printing with the launch of Vipra AM.

“With Vipra AM, we’ve leveraged the extensive know-how developed over years working on advanced process control and software for large format AM with thermoplastics and composites materials, to develop a proprietary cutting-edge metal platform that combines state-of-the-art hardware and software, with advanced robotic monitoring and automation,” says Francesco De Stefano, CEO of Caracol AM.

Vipra AM, available in two configurations (XQ and XP),  is a directed energy deposition (DED) 3D printer, or more specifically, a wire arc additive manufacturing (WAAM) 3D printer. This type of 3D printing uses metal wire as the material and a plasma arc as an energy source, similar to welding. The arc melts the wire as it’s deposited layer on top of layer by a robotic arm onto a surface, such as a multi-axis turntable.

This method of 3D printing has actually been employed in heavy industry and aerospace for years, but it’s come a long way. Today, it’s being eyed as a way manufacturing, heavy industry, defense, and aerospace can produce large metal parts at a fraction of the time and cost of traditional forging, castings, or machining. It also may be a solution for clogged industry supply chains, market pressures to innovate, sustainability targets, and faster repair and spare part delivery.

Among all the DED technologies, WAAM is the most affordable option. It can use existing arc-welding wire materials, which lowers the barrier to entry and makes it accessible to a wider range of companies. Moreover, its complex software allows for precise control of various parameters, including the thermal management and toolpath of the robotic arm, ensuring consistent and reliable results.

There is not a crowded field when it comes to WAAM 3D printers with  just about seven companies on the market with platform solutions, including AML3D, WAAM3D, Gefertec, Norsk Titanium, MX3D, RamLab, and MetalWorm.