Aconity3D Introduces Multi-Material WireDED for Industrial Production

Multi-Material WireDED Enters the Mix

Aconity3D has introduced a new multi-material head for its WireDED (Wire Directed Energy Deposition) system, capable of printing with up to 3 different materials in a single build. This development comes as industrial demand for wire-based additive manufacturing picks up across energy, mining, oil, gas, and nuclear sectors.

The AconityWIRE system features a build volume of 400 × 780 mm, coaxially fed welding wire, a 6-axis robot with a 2-axis turn-tilt table, and a heated build chamber up to 500°C. Powered by a 1000W or 1200W fiber laser, the system has been validated on Aluminum, Stainless Steel, Inconel, and Titanium wire.

Why Multi-Material Matters

The ability to combine multiple materials in a single build opens up several compelling use cases:

• Armor and hardened surfaces — combining soft materials with hard ones for wear resistance
• Large molds — with wear surfaces and conductive areas in one part
• Gradient-like parts — transitioning between material properties
• Automotive chassis components — lightweight structures with targeted reinforcement

According to Aconity3D, the system does not need significant changes to implement different materials. The multi-material head can also be added to existing systems. Rosenheim Technical University of Applied Sciences in Germany already has one in operation.

WireDED: The Under-Represented Area Ready to Grow

WireDED has long been an underrepresented area in additive manufacturing — but that may be about to change. The process offers several advantages:

• Cost-effective wire — cheaper than metal powders
• Large build volumes — ideal for big parts
• No powder handling — safer for expeditionary manufacturing and military use
• MRO potential — repair and augmentation applications

Energy industries are actively looking at this process for repair and part production. In mining, oil, gas, and nuclear, WireDED is being positioned for both new part production and maintenance, repair, and operations (MRO).

"Cheap, forward-deployed repair and manufacturing of multi-material raw DED parts could be very impactful for militaries and in industry," noted the 3DPrint.com analysis of the announcement.

The Bigger Picture

Aconity3D has a history of serving universities and researchers who use their systems to develop new processes, test exotic materials, and develop entirely new 3D printing technologies. Their Midi system can heat up to 1000°C while letting users play with every possible parameter.

With this new multi-material capability, alongside offerings from Meltio and Hybrid Manufacturing Technologies, the wire-DED segment is poised for significant growth. The technology is already seeing impact in aviation, where it's now used to produce commercial aircraft parts.

For manufacturers considering DED, the key insight is that significant machining isn't always necessary. As long as mating surfaces and functional areas are machined to spec, raw printed WireDED parts can be dramatically cheaper than fully machined alternatives.