The industrial trend of 2025: Additive manufacturing with wire
A cross-industry forecast for 2025: Additive manufacturing with wire will become increasingly important in a variety of industries. This much has been certain since FormNext 2024, where there have been noticeably more inquiries and media reports on the topics of Wire Laser Additive Manufacturing (WLAM). and Laser Metal Deposition with wire (LMD-w).
So where does this wire trend come from? While powder-based processes are already firmly established, LMD-w impresses with its high efficiency, material utilisation and versatility. In recent years, this technology has evolved from a niche solution to an indispensable method in industrial manufacturing. It offers enormous potential in metal processing, especially in the areas of additive manufacturing, 3D repair and laser coating.
In LMD-w, also known as laser beam wire deposition welding (DED-LBw), a wire is melted locally with a laser beam and applied precisely layer by layer to the component surface. This process makes it possible to produce complex structures and components with high quality and accuracy. The big advantage over powder-based processes is the uncomplicated handling and integration into existing manufacturing processes.
Advantages of laser deposition welding with wire (LMD-w)
The use of wire as a filler material brings with it numerous advantages that make LMD-w particularly attractive for industrial applications. This technology offers an excellent alternative to traditional manufacturing processes and powder-based additive methods.
The most important advantages at a glance:
- 100% material utilisation: While 10-20% of the material is lost in powder-based processes, the entire material is used efficiently in the wire process.
- High processing speed: The higher deposition rate of the wire leads to faster processing times.
- Safe and clean process: Wire materials do not produce harmful dust and are easier to store and handle.
- Wide material availability: Standardised wire materials are available on the market in a wide variety and quality.
- Little influence on the base material: The precise energy input protects the material from unwanted changes.
- Fine surface quality: Components with LMD-w have a high surface quality, which reduces the amount of post-processing required.
The combination of these properties makes LMD-w suitable for the production of new components as well as for the economical repair and coating of existing components.
The ProFocus technology from OSCAR-PLT – tailor-made for the highest demands
With the ProFocus technology, OSCAR-PLT offers a powerful solution for laser deposition welding with wire AND powder. This system was specifically developed to take full advantage of the LMD-w process while offering maximum flexibility in material choice: changing from wire to powder takes under 10 seconds.
A feature of ProFocus technology that customers particularly value is its coaxial design, which enables direction-independent processing of wire and powder materials. The ring-shaped laser beam ensures constant, even energy distribution, achieving a stable melting process and optimal material binding. Additionally, ProFocus technology offers exceptional process reliability through its advanced control and monitoring systems.
These properties make ProFocus technology particularly attractive for companies that want to future-proof their manufacturing and repair processes.
The strengths of ProFocus technology include:
- Maximum flexibility through the use of wire and powder materials in one system, with material changes in just a few seconds
- Direction-independent welding through a coaxial material feed
- Effective process monitoring with integrated HDR camera, temperature detection and functions such as StartControl, WireWatcher and HeightControl
- Seamless integration into existing manufacturing systems for a smooth production process, even automated
- Higher surface quality means less mechanical finishing and less wear on tools such as CNC milling
These properties make ProFocus technology particularly attractive for companies that want to future-proof their manufacturing and repair processes.

Sustainability and economic efficiency
In addition to the technical performance, the LMD-w process also offers significant advantages in terms of sustainability and cost savings. The resource-saving use of materials, the extension of the service life of components and the option of repairing instead of purchasing new ones actively contribute to reducing CO₂ emissions.
At the same time, companies benefit from both a newfound independence from international supply chains and reduced costs for storing spare parts. The ProFocus technology makes it possible to produce these as needed and avoid delivery bottlenecks.
Get started now with ProFocus and LMD-w
Additive manufacturing with wire opens up new perspectives for the production, repair and coating of metal components. With ProFocus technology, OSCAR-PLT offers a powerful, flexible and economical solution that meets the growing needs of the industry.
Use the potential of laser deposition welding with wire AND powder for your company and let our experts advise you. Make an appointment now with Dr.-Ing. Tobias Gustmann or Ulf Jasnau and find out how you can make the impossible possible with ProFocus.
Contact us today and let’s shape the future of your production together!