AMA: Energy 2026: [INTERVIEW] How Large-Scale Metal AM Is Helping Energy OEMs Break Free From Forging and Casting Delays

Why It Matters

Large‑scale AM provides energy manufacturers a viable alternative to costly, slow forging and casting, reducing inventory burdens and enhancing supply‑chain resilience. Faster qualification will accelerate industry‑wide adoption and lower maintenance costs for critical infrastructure.

Key Takeaways

• WAAM deposits 1‑5 kg/h, suited for massive, thick components
• LW‑DED deposits 0.4‑0.6 kg/h, yields finer surface finish
• Nickel‑alloy parts can save $40‑$50k versus traditional machining
• On‑demand AM cuts spare‑part inventory and tooling costs
• Qualification of Inconel, 718, Haynes 282 remains primary barrier

Pulse Analysis

Additive manufacturing is moving from a niche prototyping tool to a production‑ready solution for the energy sector. Wire‑based processes such as WAAM and laser‑wire DED enable near‑net‑shape builds of large, high‑value components, dramatically cutting material waste and machining time. For turbine housings, manifolds, and other nickel‑based parts, the speed advantage of WAAM and the surface quality of LW‑DED translate into cost reductions of $10,000 to $50,000 per component, making a compelling business case for firms grappling with long lead times and constrained supplier bases.

Beyond cost, the strategic impact of large‑scale AM reshapes spare‑parts logistics. Energy operators can replace bulky physical inventories with qualified digital models, printing critical spares on demand when original tooling is obsolete or unavailable. This shift not only lowers capital tied up in inventory but also improves equipment uptime, as replacement parts can be produced locally and quickly. Repair and refurbishment of aging infrastructure further benefit, with DED allowing precise rebuilds that extend service life without the need for full re‑manufacturing.

The remaining hurdle is regulatory and material qualification. Energy systems demand rigorous certification, especially for alloys like Inconel 625, 718, and Haynes 282, whose additive‑manufactured properties must match those of traditionally forged parts. Industry consortia and OEMs are investing in standardized testing, traceability, and inspection protocols to bridge this gap. As these frameworks mature, the adoption curve for large‑scale AM will steepen, unlocking broader efficiencies across the power generation supply chain.