Wire Arc Additive Manufacturing (WAAM) is a manufacturing method within the Direct Energy Deposition (DED) family of Additive Manufacturing technologies. Metal is deposited layer by layer by a welding robot which consists of a welding torch attached to a robotic arm, programmed to precisely lay down material according to a 3D CAD model. DED-Arc was selected by DEEP manufacturing as the preferred manufacturing method for Sentinel pressure hulls due to its high deposition rates, scalability, and support for multiple metal feedstock materials.

DEEP has invested in a significant number of DED-Arc systems comprising Valk Welding torches, Panasonic robot arms, and RAMLAB control and monitor hardware and software. These can be used as single systems to produce parts across a wide range of materials and geometries up to 2.8⌀ x 3.2m. However, in order to produce the large segments for a Sentinel pressure hull, DEEP Manufacturing is undergoing an ambitious technology development programme with RAMLAB to develop multi-arm collaborative DED-Arc. This will see six individual DED-Arc systems arranged in a hexagonal configuration, working synchronously to produce 30T+ hull segments at world leading deposition rates. Once operational, this multi-arm system will be capable of prints up to 16.1m⌀ x 3.2m.

In parallel, DEEP Manufacturing is working closely with DNV to achieve approval of the DED-Arc process for safety critical subsea applications. Collaboration with other industry leaders has accelerated creative problem-solving and breakthrough technological development, and we’re on track to deliver the first ever Additively Manufactured pressure vessel certified for human occupancy.