NP Aerospace and the Digital Manufacturing Centre have manufactured the suspension and differential support bracket for the Mastiff armored vehicle using WAAM. The 110 kg part was printed in 60 hours without the need for molds, directly challenging traditional casting and forging. This process enables a 50% reduction in lead times and eliminates tooling costs.
Arc Metal Deposition: Precision Without Tooling 🔧
WAAM (Wire Arc Additive Manufacturing) technology builds layers of molten metal using an electric arc and wire, guided by a robotic arm. For the Mastiff bracket, a high-strength steel alloy was used. The result is a structural part that meets military specifications without the long lead times for manufacturing molds or dies. This enables low-volume production and rapid design iteration, something unfeasible with conventional methods.
Goodbye Molds: Casting Goes on Pause ⏸️
While traditional casters wait weeks for a mold, here you press print and in 60 hours you have a 110 kg bracket ready. Of course, the machine's coffee must be well loaded, because a failed print at 59 hours hurts more than a pothole on the firing range. But hey, that's what rapid prototypes and panic buttons are for.