In manufacturing processes involving industrial robots, collisions are a significant risk due to the high number of degrees of freedom. This is particularly the case in complex processes such as wire arc additive manufacturing, where metal is printed using a welding unit mounted on the robot. Simulations can be used before the operating phase to identify potential collisions between the industrial robot and itself, the workpiece clamping, or the workpiece. Even after intensive testing, a collision can still occur during the operating phase if any environmental condition differs from the simulation. This could be due to a change in motion caused by actual measured values or the modification of parameters by humans or an adaptive system. This work presents a concept for online real-time collision avoidance in robotic wire arc additive manufacturing. The concept is based on adopting simulations from virtual commissioning for the use in the operating phase. The concept is then realized with the help of a real industrial robot. The resulting solution’s novelty is the virtual commissioning-based online collision avoidance of wire arc additive manufacturing with industrial robots.