Fronius Launches Additive Cell for Industrial Metal 3D Printing

A complete welding cell built for metal additive manufacturing

Welding system manufacturer Fronius has introduced a new Additive Cell based on Wire Arc Additive Manufacturing (WAAM). The system is designed as a coordinated end-to-end solution for producing high-quality metal components in automotive, aerospace, oil and gas, and mining applications.

Inside the cell, the CMT Additive Pro and Fronius iWave handle the actual welding process while the Polaris system manages overall control. Fronius says every component was designed to work as a single, stable manufacturing process rather than a collection of separate parts bolted together.

Why WAAM is gaining ground

WAAM is becoming a practical option for 3D printed spare parts, prototypes, and complex one-off components. The method deposits metal wire layer by layer using a welding arc, which keeps material consumption low compared to conventional machining. It also handles irregular geometries that would be expensive or impossible to produce through casting or milling.

Manuel Stinglmayr, business development at Fronius International, noted that WAAM enables decentralized, location-dependent manufacturing without complex production lines. That matters for companies that need large metal parts on short timelines but cannot justify the cost of traditional tooling.

Software and process control

The Additive Cell runs Fronius's Vectris software bundle, which combines the machine tool service kit, post-processor, and an integrated kinematic model on one platform. The system can detect different component regions and adjust welding parameters on the fly, switching between settings for outer walls, panels, infill, or component joints without manual intervention.

The post-processor translates build styles directly into welding commands for the robot. That removes the need for separate CAM steps and reduces the chance of operator error when switching between part geometries.

Services and certified recipes

Fronius offers consultation, feasibility studies, process development, and production services from its prototyping and manufacturing centre. The company can also develop and certify welding parameters for specific materials and license those validated recipes to customers. The goal is to shorten the path from first prototype to qualified production part.