Fronius unveils CMT Additive Pro for wire-based DED
October 9, 2024
Fronius International GmbH, based in Österreich, Austria, has announced CMT Additive Pro, a 3D-optimised welding system for wire-based Directed Energy Deposition (DED) Additive Manufacturing. The CMT Additive Pro is reported to provide an especially even layer structure, as well as high quality and stability.
“The right welding path, with the right welding parameters and processes, is crucial for a good result in metal 3D printing,” explained Philipp Roithinger, an expert in Additive Manufacturing at Fronius. “However, this requires a high-performance welding system that precisely ensures the accuracy of the welding torch.”
Fronius has been offering Cold Metal Transfer (CMT), a highly stable, easily controllable, and relatively cool welding process, for decades. The company has now optimised CMT specifically for metal Additive Manufacturing, incorporating all its accumulated expertise into the development of Fronius CMT Additive Pro.
An integrated arc-on rate stabiliser ensures a consistent wire speed, resulting in an even and predictable build-up of layers. This significantly improves the overall stability of the manufacturing process.
“Another innovation is the adjustable heat input, which ensures consistency in the height and width ratio of the bead, regardless of the current temperature of the base material or the previously welded layer. Weld layers usually become wider and flatter as the component heats up,” Roithinger added. “The power correction feature counteracts this, so that identical welds can be stacked on top of each other, layer after layer.”
The start of the weld within the construction process is another important criterion for metal Additive Manufacturing. Welding errors or cambers in the area where the weld was started can affect the quality of the result. Fronius claims to have the solution to this with the Pulsed Hot Start function, which simultaneously achieves sufficient penetration and a constant layer height by starting welding within the pulsed arc. Here, the whole process is controlled automatically, so no extra settings are necessary.
At the company’s 900 m² prototyping centre in Wels, Austria, it has several isolated robot cells and systems. It offers full service, including offline programming and simulations, metallurgical investigations, 3D component measurement, complete data documentation, and much more. Tailor-made solutions are developed for individual requirements, customers’ Additive Manufacturing processes are optimised, and highly complex components are realised.
The company supports the production of the initial prototypes and pre-series and enables a smooth entry into the AM process. In addition, recommendations on the welding process, profitability, quality and implementation options, or the costs for the prototype and the start of production are provided.