A Grand 5.3-Meter Metal 3D-Printed Sculpture Debuts in Hong Kong: WAAM Technology by AMmake Revolutionizes Complex Architectural Creations

PanDen 2024-11-21 00:38 Application

In June 2024, a monumental metal 3D-printed sculpture was officially unveiled in the "Wedding Garden" of the new headquarters of Hong Kong's Immigration Department in Tseung Kwan O. This awe-inspiring ...

The sculpture, measuring an impressive 5.3m x 4.8m x 3.8m and weighing over 2000kg, resembles a delicate, flowing bridal veil in pure white. However, in fact, it is a robust stainless-steel creation that epitomizes the seamless integration of artistic expression and cutting-edge 3D printing technology.

Photo of “Weave of Love” veil sculpture on-site

Commissioned by the Hong Kong Immigration Department and designed under the guidance of the Architectural Services Department, the project saw the collaboration of several institutions, including the Department of Civil and Environmental Engineering at The Hong Kong Polytechnic University, the Emerging Technologies Institute of The University of Hong Kong, and CGN Suzhou Nuclear Power Research Institute Co., Ltd. AMmake（融速科技） provided comprehensive support, encompassing technological development, customized solutions, equipment design, and rigorous testing. The finished sculpture met and exceeded all client quality and performance expectations.

WAAM Technology Bridges Art and Innovation,

Crafting a Unique Wedding Landmark

Named “Weave of Love,” the sculpture draws inspiration from the ethereal grace of a bride’s veil. Its 1,312 intricately hollowed-out heart motifs intertwine, the two true love hearts of the newlyweds are intertwined to form 1,314 hearts, symbolizing eternal love and being full of artistic creativity and romantic implications. The design required both a sense of flowing delicacy and unyielding durability, achieved through AMmake's Wire Arc Additive Manufacturing (WAAM) 3D metal printing technology.

SCULPTURE: Gracefully Curved with Heart-shaped Part in Close-up, Full of Details

With its sweeping curves and heart-shaped details, the sculpture posed significant design challenges. WAAM, a high-precision technique for fabricating large, complex metal components, offered unmatched design freedom and scalability while keeping costs and material waste to a minimum. By melting metal wire with an electric arc, WAAM enabled the meticulous layer-by-layer construction of this intricate masterpiece. AMmake’s refined approach ensured both the artistic vision and structural integrity were brought to life.

Leveraging its expertise in WAAM, AMmake utilized in-house developed arc wire feeding equipment, delivering end-to-end metal additive manufacturing capabilities. With over 600 completed projects to date, AMmake continuously optimizes design processes to minimize production timelines, reduce costs, and lower environmental impact.

WAAM Technology of AMmake

Tailored Printing Solutions Tackle Large-Scale,

Complex Structure Challenges

The “Weave of Love” sculpture is composed of interlinked quadrilateral grid tubes with a highly intricate and curvaceous structure. Its considerable dimensions posed challenges in controlling deformation during the printing process and demanded precise adjustments for steep angles and fine details. AMmake rose to the occasion with a bespoke printing solution that married artistic ingenuity with technical precision.

First, a draft molding analysis identified regions with sharp angles. These areas were divided into zones for separate printing, incorporating strategic supports to ensure stability. After printing, the sections were welded together seamlessly using specialized jigs.

Mold analysis diagrams for different perspectives

AMmake’s proprietary slicing software allowed precise planning of printing paths and parameter controls. Combined with digital twin technology, the software provided real-time visualization of printing dynamics, ensuring meticulous control throughout the process.

Plan the Printing Path in Advance

To perfect quality, the printing methodology was refined in two critical areas. Vertical-direction printing underwent five rounds of parameter adjustments to optimize wall thickness and aesthetics. For large-angled sections, adjustments enabled stable 50° angle printing, successfully mitigating deformation risks by aligning closely with digital models.

Sample prints for quality validation

Advanced Eight-Axis Printing Equipment

Ensures Precision and Reliability

The sculpture’s fabrication relied on AMmake’s RS-R1 and RS-L2 large-scale vertical rail arc additive printing systems. Equipped with advanced eight-axis motion control and proprietary calibration algorithms, these systems achieved exceptional accuracy and efficiency, ensuring timely project completion without compromising quality.

Printing in progress with RS systems

The RS systems feature a suite of sensors, including height sensors for consistent layer heights, single-point infrared thermometers for precise interlayer temperature control, and AMmake’s innovative melt pool monitoring cameras. These tools provided clear, real-time visuals of the molten material, unaffected by the intense light of the welding arc, ensuring flawless results.

Printing in progress with RS systems

3DP sand casting Printing by 3DPTEK.: Accelerating the Rapid Manufacture of Large-scale Castings** Sand Mold 3D Printing Pioneer 3DP Technology, Inc. Acquires Casting Manufacturer Zhonghongtong to Accelerate Applications of 3D Casting in High-Voltage Electrical Systems