ROBOTIC METAL ADDITIVE MANUFACTURING FOR LARGE-SCALE PARTS

Caracol’s WAAM system integrates two specialized deposition heads, each equipped with advanced power sources tailored for distinct production goals:

• Extreme Quality – Designed for applications that demand precise detail and strict tolerances, this deposition head operates with a high-energy plasma power source, achieving high-speed metal deposition. By melting feedstock wire layer by layer, it consistently produces superior build quality suited for intricate components.
• Extreme Productivity – Engineered for large-scale, high-throughput manufacturing, this head uses Cold Metal Transfer (CMT) technology powered by a low-heat welding source. The system’s synchronized short-circuiting arcs facilitate efficient, distortion-free metal deposition, layer by layer. This setup minimizes thermal impact, optimizing productivity and ensuring robust structural integrity.

Caracol equipped Vipra AM with a 9-axis industrial robotic arm and positioner kinematics to enhance flexibility for 3D printing complex geometries, enabling complex building strategies like non-planar slicing, multi-angle welding, and printing on parts with overhangs. The print volume can be expanded by placing the robot on a rail.

Caracol developed Eidos Manufacturing software, leveraging years of experience in LFAM design, slicing, and robotic cinematics. The suite complements Vipra AM, offering full control and flexibility. The Builder simplifies slicing and parameter setting with an intuitive interface. It visualizes the robotic platform in real time, allowing you to choose printing approaches and ensuring accurate tool paths. The Monitoring system ensures quality and repeatability by analyzing sensor data and robot position, creating a real-time digital twin. This system tracks performance, maintains records, and optimizes production for consistent results.

Vipra AM features core sensors for real-time monitoring of key parameters, including layer geometry, thermal development, and gas flow. Laser scanning, welding cameras, thermal cameras, and pyrometers ensure precise tracking and consistent results throughout the build process.

The advanced Vipra AM enclosure offers optimal production space with enhanced safety, environmental control, and seamless integration. It features a centralized Machine HMI for controlling functions like fume extraction, lighting, doors, and monitoring. Tailored fume management keeps the air clean, while the surveillance system ensures operator safety and equipment integrity. Additional features, such as shadow-free lighting, an automatic door, and a linear track system for material handling, further enhance safety, ease of operation, and precision.