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Wire and Arc Additive Manufacturing (WAAM) is a 3D printing technique, where robotic welding is used to deposit melted metallic material incrementally in order to additively manufacture steel components. The method promises to be efficient in material use and allows for geometric freedom in the design of structural elements. It can be also used to customize mass-produced steel profiles by placing additional WAAM material in highly stressed areas. In order to quantify the sustainability potential of such customized solution, the current paper considers Hybrid WAAM—IPE 160 beams under a set of design situations, where standard IPE 200 section would be traditionally used. As a result, a reduction of element mass up to 28%, and CO2 equivalent up to 25% is possible. This study also highlights the influence of Life Cycle Assessment (LCA) assumptions. Depending on geographical location and production arrangement, the CO2 equivalent footprint of a steel element can vary largely, even by 90%.

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Quantification of Potential of Hybrid Wire and Arc Additively Manufactured I-Beams for Resource-Efficient and Sustainable Steel Structures

  • 会议论文

  • 发表日期：

    2025年

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  • Hannes Eichler,
  • Bartłomiej Sawicki,
  • Harald Kloft

摘要

Wire and Arc Additive Manufacturing (WAAM) is a 3D printing technique, where robotic welding is used to deposit melted metallic material incrementally in order to additively manufacture steel components. The method promises to be efficient in material use and allows for geometric freedom in the design of structural elements. It can be also used to customize mass-produced steel profiles by placing additional WAAM material in highly stressed areas. In order to quantify the sustainability potential of such customized solution, the current paper considers Hybrid WAAM—IPE 160 beams under a set of design situations, where standard IPE 200 section would be traditionally used. As a result, a reduction of element mass up to 28%, and CO2 equivalent up to 25% is possible. This study also highlights the influence of Life Cycle Assessment (LCA) assumptions. Depending on geographical location and production arrangement, the CO2 equivalent footprint of a steel element can vary largely, even by 90%.