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In the ITEA project FAMILIAR, Fraunhofer IAPT and the institute’s project partners have developed a digital assistance system using machine learning and mixed-reality (XR) glasses for robotic Wire Arc Additive Manufacturing (WAAM). The assistance system enables companies with little prior knowledge to utilize WAAM as efficient yet challenging 3D printing technology.
Hamburg/Germany, November 5, 2025 – The consortium of the ITEA project FAMILIAR has developed an architecture for federated machine learning (FedML) with head-mounted mixed-reality (XR) displays and analyzed it in use cases. In one of the application scenarios, the consortium leader consider it and the partners Fraunhofer Research Institution for Additive Manufacturing Technologies IAPT, NXRT, and Pumacy Technologies developed a digital assistance system for setting up robotic Wire Arc Additive Manufacturing.
FAMILIAR: Safe and Efficient Machine Learning
The FAMILIAR project aims to optimize workflows and increase efficiency in manufacturing companies through machine learning (ML). Collaborative learning between edge devices and decentralized data storage ensures data security and opens up the advantages of machine learning as well as virtual and augmented reality (VR and AR) to sensitive industries. Use cases from the automotive industry and additive manufacturing (AM) served for analysis and validation in the project.
In a sub-project of the ITEA project FAMILIAR, Fraunhofer IAPT worked with project partners on a setup assistance for robotic Wire Arc Additive Manufacturing (WAAM). The Fraunhofer IAPT focused on developing the system architecture in the 3D printing facility, integrating sensors, developing data streams and interfaces, as well as evaluations and tests.
Challenges of Robotic Wire Arc Additive Manufacturing (WAAM)
WAAM is part of the Directed Energy Deposition (DED) processes. The additive manufacturing technology builds components layer by layer by melting metal wire through an arc. The advantages of WAAM over other 3D printing methods include high speed and efficient material usage. WAAM produces large structures faster and more cost-effectively than powder processes. Additionally, the components are characterized by high strength and favorable mechanical properties.
However, robotic Wire Arc Additive Manufacturing is complex and requires extensive knowledge of production processes. The setup of the robotic 3D printing process determines the quality of the process and the components. For example, insufficient clamping of the metallic substrate plates can lead to deformation of the substrate plate and costly rework or scrap production.
Digital Assistance System: Quick and Safe Set Up of WAAM Processes
The new assistance system guides operators through the setup of the robotic 3D printing process using mixed-reality (XR) glasses. Sensor data from an in-process stereo camera trains the machine learning model that calculates the setup parameters for robotic Wire Arc Additive Manufacturing.
The resulting digital assistance system eliminates inefficient process steps and reduces the preparation effort for WAAM production by half. Beyond the time savings in the preparation of additive manufacturing, the assistance system contributes to improving the quality of WAAM components.
About FAMILIAR
ITEA is a EUREKA cluster for software innovations that support European companies in digitalization. The 3-year ITEA project FAMILIAR (Holistic Federated AI Development for Mixed-Reality Applications in Europe) involved project partners from Germany, Turkey, and Austria. The application case for additive manufacturing was funded by the Federal Ministry for Research, Technology, and Space (BMFTR) and the Austrian Research Promotion Agency FFG.
More information on FAMILIAR is available at https://itea4.org/project/familiar.html
About Fraunhofer IAPT
The Fraunhofer IAPT stands for sustainable innovations in the field of additive manufacturing. Its portfolio includes research and development along the entire AM manufacturing route – from unique component designs and system solutions, including process and material levels, to factory planning and virtualization. All aspects of the additive manufacturing process are comprehensively considered from the initial idea and feasibility to industrial implementation in new or existing production environments. A particular focus is placed on socially relevant future topics in the fields of life sciences, energy, mobility, as well as security and defense. Our overarching goal is to ensure that additive manufacturing technologies are industrially applied, significantly contributing to increased productivity, resource conservation, resilience, and prosperity.
Press Contact
M.A. Carola Dellmann
Head of Marketing & Communication
Fraunhofer IAPT
Email: marketing@iapt.fraunhofer.de
Phone: +49 40 484010-500
Consider it
Tobias Koch
koch@consider-it.de
Fraunhofer-Einrichtung für Additive Produktionstechnologien IAPT
Julian Ulrich Weber
julian.ulrich.weber@iapt.fraunhofer.de
NXRT
Lukas Stranger
lukas.stranger@nxrt.io
Pumacy Technologies
Dr. Bernd Bredehorst
bernd.bredehorst@pumacy.de
https://itea4.org/project/familiar.html More on FAMILIAR
https://www.iapt.fraunhofer.de/en.html More on Fraunhofer IAPT
https://www.bundesregierung.de/breg-en/federal-government/ministries/federal-min... More on the Federal Ministry for Research, Technology, and Space (BMFTR)
https://www.ffg.at/en More on the Austrian Research Promotion Agency (FFG)
Wire Arc Additive Manufacturing (WAAM) is part of the Directed Energy Deposition processes. It is ba ...
Source: Fraunhofer IAPT
Copyright: Fraunhofer IAPT
WAAM facility at Fraunhofer IAPT
Source: Fraunhofer IAPT
Copyright: Fraunhofer IAPT
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English
Wire Arc Additive Manufacturing (WAAM) is part of the Directed Energy Deposition processes. It is ba ...
Source: Fraunhofer IAPT
Copyright: Fraunhofer IAPT
WAAM facility at Fraunhofer IAPT
Source: Fraunhofer IAPT
Copyright: Fraunhofer IAPT
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