Wire-based additive manufacturing: Why WLAM is gaining importance in industry
Updated in September 2026: Wire-based additive manufacturing continues to evolve from a specialised technology into an industrial solution for manufacturing, repair and coating applications.
Wire-based additive manufacturing is becoming increasingly important across a wide range of industries. Wire Laser Additive Manufacturing (WLAM), also known as Laser Metal Deposition with Wire (LMD-w), offers attractive opportunities for additively manufacturing metal components, selectively repairing damaged areas and applying functional coatings.
While powder-based processes have been established for some time, wire-based processes offer particular advantages in terms of material utilisation, comparatively straightforward material handling and effective automation. This makes the technology an increasingly attractive industrial addition to existing manufacturing and repair processes.
In LMD-w – also referred to as laser cladding with wire or DED-LBw – a metallic wire is locally melted using a laser beam and precisely deposited onto a component. This allows existing geometries to be extended, worn areas to be reconstructed or new structures to be built up layer by layer.
For a detailed overview of the process, its advantages, materials, process parameters and industrial applications, please refer to our process knowledge page on laser cladding with wire.
Advantages of laser cladding with wire (LMD-w)
Using wire as a filler material offers numerous advantages that make LMD-w particularly attractive for industrial applications. The technology provides an effective alternative to conventional manufacturing processes and powder-based additive manufacturing methods.
The most important advantages at a glance:
- High material utilisation: The wire is fed directly into the process zone and is almost completely processed. Powder losses caused by overspray or extraction are avoided.
- High deposition rates: Depending on the material, component geometry and process configuration, the wire-based process enables efficient material deposition.
- Simple material handling: Welding wires are comparatively straightforward to store, transport and feed. The typical requirements associated with handling metal powders do not apply.
- Wide range of materials: Numerous established welding consumables are available in wire form. Depending on the application, flux-cored wires can also be used.
- Controlled energy input: The locally concentrated laser energy enables the heat input, penetration and dilution to be precisely controlled.
- Near-net-shape material deposition: Defined weld beads can reduce excess material and minimise the amount of subsequent milling, grinding or other finishing work required.
- Effective automation: Process parameters such as laser power, wire feed rate and travel speed can be digitally controlled and synchronised.
The combination of these characteristics makes LMD-w suitable both for manufacturing new components and for the cost-effective repair and coating of existing parts.
ProFocus technology from OSCAR PLT – laser cladding with wire and powder
With ProFocus, OSCAR PLT offers a modular laser cladding system for wire and powder. The technology is suitable for the repair, coating and additive manufacturing of metal components and can be integrated into CNC systems, robotic systems or mobile processing solutions, depending on the application.
Six individually controllable laser beams are arranged concentrically around the central material feed. The coaxial wire feed enables direction-independent processing, making it particularly suitable for automated processes and complex toolpaths.
The strengths of ProFocus include:
- Processing of wire and powder materials within a modular system platform
- Coaxial wire feed for direction-independent processing
- Defined energy input using six individually controllable laser beams
- Controlled penetration and low dilution
- Integration into CNC systems, robotic systems or mobile solutions
- Process control and assistance functions for stable and reproducible processes
- Support from the initial feasibility assessment through to productive integration
These characteristics make ProFocus technology particularly attractive for companies looking to make their manufacturing and repair processes efficient, flexible and future-ready.
A focus on sustainability and cost-effectiveness
Laser cladding with wire can contribute to a more efficient use of materials and existing components. By selectively rebuilding worn areas, it may not be necessary to replace the entire component. Depending on the application, this can reduce material consumption, manufacturing effort, costs and lead times.
In additive manufacturing, material is also deposited only where it is required. This can provide both economic and resource-related benefits, particularly for high-value, large or difficult-to-source components. However, whether repair or additive manufacturing is a suitable solution must always be assessed individually based on the component, material and specific application.
Get started with ProFocus and LMD-w
Wire-based additive manufacturing opens up new possibilities for the production, repair and coating of metal components. With ProFocus technology, OSCAR PLT offers a powerful, flexible and cost-effective solution designed to meet the growing demands of industrial manufacturing.
Harness the potential of laser cladding with wire and powder for your company and benefit from expert advice tailored to your application. Schedule an appointment with Dr.-Ing. Tobias Gustmann or Ulf Jasnau and discover how ProFocus can help you make the impossible possible.
Contact us and let us shape the future of your manufacturing together!