DEEP Manufacturing and Fortius Metals Partner to Scale Production of Complex Multi-Material Metal Parts

DEEP Manufacturing and Fortius Metals have collaborated to build a multi-material metal cylinder using DEEP Manufacturing’s synchronized multi-robot wire arc additive manufacturing (WAAM) system, a form of industrial 3D printing that uses welding to build large metal parts layer by layer.

The goal is to demonstrate that multi-material metal deposition – combining advanced alloys within a single, continuous build – can be executed with the precision, repeatability and process control that true production environments demand.

The project represents an exciting step forward for the advanced Manufacturing sector as a whole. It demonstrates how multi-material wire arc DED can be scaled toward production, opening new possibilities for manufacturers looking to push the boundaries of what’s achievable with larger, more complex, and higher-performing metal components.

The collaboration builds on DEEP Manufacturing’s recent work scaling synchronized multi-robot WAAM that identified thermal distortion and toolpath generation as the main barriers to larger, more complex builds and flagged multi-material deposition as a key opportunity – both of which this project sets out to address.

The two companies bring complementary strengths: DEEP Manufacturing contributes large-format printing, multi-robot deposition, and real-time monitoring that allow demanding geometries and material combinations to be built at scale. Fortius Metals contributes thermal and mechanical simulation, toolpath design, and advanced welding wires that predict and manage how a part behaves as it is built, reducing guesswork before and during manufacture.

The collaboration is among the first to be announced since DEEP Manufacturing opened its 50,000 sq ft Houston facility, a US$ 10 million investment aimed at bringing large-format WAAM closer to North American customers and shortening lead times for high-integrity components.

Peter Richards, CEO, DEEP Manufacturing, said: “Multi-material manufacturing will help transform industries that rely on parts performing in the most demanding environments. But getting there takes more than depositing metal. It takes process knowledge, monitoring, and control at scale. This project is about proving those capabilities can come together to move hard problems closer to production.”

Jeph Ruppert, CEO, Fortius Metals, added, “By combining simulation, toolpath design, and advanced wire with a highly capable printing platform, we can explore what’s genuinely possible for complex parts. Working with DEEP Manufacturing lets us apply our modelling and materials expertise to a real, demanding structure.”

The project will start with test samples and a smaller test cylinder before the main print, scheduled for mid-June to early July. Both companies plan to share updates and visual content at each stage, with a follow-up announcement on completion.

Image Source: Deep Manufacturing