Caracol Develops Vipra AM Robotic Metal DED 3D Printing Platform for Manufacturing Large-Scale Metal Parts

Caracol has developed a turnkey Vipra AM robotic platform with integrated hardware, software and automation to manufacture advanced large-scale metal parts and enhance manufacturers’ flexibility, precision and performance.

The metal 3D printing system is a large-scale direct energy deposition (DED) platform that leverages wire arc additive manufacturing (WAAM) processing, which is seamlessly incorporated into the proprietary system. The platform was created to maximize users’ flexibility, control and performance, thereby expanding large format additive manufacturing’s (LFAM) possibilities to a broader range of applications.

“At Caracol, we believe that the future of manufacturing lies in combining a strong application focus with advanced innovative technologies that reshape the capabilities of industrial production lines,” says Francesco De Stefano, Caracol AM CEO. “With Vipra AM, we’ve leveraged the extensive know-how developed over years working on advanced process control and software for large-format AM with thermoplastics and composites materials, to develop a proprietary cutting-edge metal platform that combines state-of-the-art hardware and software, with advanced robotic monitoring and automation. Thanks to this innovative technology, we want to enlarge the possibilities of industrial manufacturers to produce their most complex large-scale projects.”

Caracol offers two Vipra configurations:

• Vipra XQ (Extreme Quality) utilizes plasma arc deposition technology to produce extremely high-quality components with exceptional finishing and precision. It can process a broad range of metals, including stainless steels and titanium alloys. The system is well suited for large-scale, high-strength, high-integrity parts for sectors such as aerospace (such as load-bearing brackets and structural components) and energy (such as valves, gauges and structural piping connectors).
• Vipra XP (Extreme Productivity) is focused on maximizing productivity and minimizing operating costs in the manufacturing process of complex large-scale metal projects. Its throughput combined with its ability to print aluminum and nickel-based materials make the system well suited for parts where lead times and lightweight are critical, such as transportation industries (such as automotive components, aerospace pressure vessels, marine propellers) and lower end architectural applications (such as sculptures and lightweight organic structures).

In both product configurations, Vipra AM was built to produce successfully advanced applications such as load-bearing finished parts, lightweight structures, high-temperature, high durability autoclave and curing molds, cladding, repair and on-demand spare parts.

“The launch of Vipra AM represents a significant breakthrough for the metal additive manufacturing industry,” says Gianrocco Marinelli, Metal Additive Manufacturing Director at Caracol. “In today's competitive market, manufacturers face mounting challenges, from material waste and long lead times to the pressure of reducing costs while maintaining high performance. Vipra AM introduces cutting-edge capabilities and complements existing processes, enabling hybrid production models that combine legacy techniques with advanced metal deposition to help manufacturers optimize production lines, reducing waste, accelerating lead times and driving overall efficiency without overhauling their entire operations.”