ABS and Radian Forge Target Digital Qualification for WAAM Compone

Classification society ABS and US manufacturer Radian Forge have signed a joint development project to test whether digital manufacturing data can be used to qualify metal components made by wire arc additive manufacturing. The project will assess whether process parameters, real-time sensor data, inspection records and material test results can reliably verify and validate WAAM-produced parts. The work aims to build confidence in additive manufacturing as the maritime industry seeks faster ways to source critical components.

 

The Joint Development Project

 

Under the agreement, Radian Forge will manufacture components for testing and validation, collect manufacturing and sensor data, and carry out testing. ABS will provide independent technical review, evaluate the results and assess the proposed methodology and how it might be applied. The project combines Radian Forge’s production capability with ABS’s role as an independent verifier of marine equipment. Its findings could inform how classification societies approve additively manufactured parts in future.

The central question is whether data captured during manufacturing can serve as evidence of a part’s quality. Conventional qualification relies heavily on destructive testing of sample parts and extensive inspection after production. If digital records prove reliable, they could reduce the testing burden and shorten approval times. This would make additive manufacturing more practical for parts needed quickly.

 

How WAAM Works

 

Wire arc additive manufacturing uses an electric arc and standard welding wire to build metal parts layer by layer, often using industrial robots. It is suited to large metal components that would otherwise require casting or forging. Because parts are built from a digital design, they can be produced without the tooling and moulds that traditional methods require. This makes the process attractive for low-volume or replacement parts.

Consistency is the main challenge for additive manufacturing in safety-critical applications. Small variations in heat input, deposition rate or cooling can affect a part’s strength and internal structure. Monitoring these variables in real time could show whether each part was built within acceptable limits. That is the type of evidence the joint project aims to validate.

 

Addressing Supply Chain Pressures

 

The maritime industry faces long lead times and limited availability for many metal components, particularly large castings and forgings. Shortages can keep vessels out of service while operators wait for replacement parts. Additive manufacturing offers a way to produce parts on demand, closer to where they are needed. However, operators and regulators need confidence that these parts perform as well as conventionally made components.

Radian Forge Chief Executive Jeff Yeager said traditional manufacturing timelines can create significant challenges when critical components are needed. He said the company aims to build confidence in a process that can respond to those needs. Yeager added that working with ABS allows a rigorous evaluation of how process data and material performance can support that goal. Radian Forge says its process can cut production lead times by 40 to 80 percent.

 

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Radian Forge’s Growth

 

Radian Forge is based in Portsmouth, Virginia, and makes large-scale metal parts for maritime and defence customers, mainly the US Navy. The company combines industrial robotics, WAAM and digital process monitoring as an alternative way to produce critical metal components. In February 2026, Virginia’s governor announced that the company plans to invest US$10.5 million to expand its Portsmouth operations, creating 53 jobs. Radian Forge has also closed a US$2.5 million seed funding round led by Veteran Ventures Capital.

The company’s growth reflects wider efforts to rebuild US industrial capacity for naval shipbuilding and repair. Domestic heavy manufacturing capacity has declined, creating bottlenecks for large metal components. The US Navy has been examining additive manufacturing to ease supply constraints for its fleet. Independent validation from ABS could help Radian Forge win commercial maritime and offshore customers as well.

 

ABS’s Role in Additive Manufacturing

 

ABS already supports the adoption of additive manufacturing through technical requirements and guidance, including its Requirements for Additive Manufacturing. Classification society rules set the standards that ship and offshore components must meet to be approved. As additive manufacturing matures, these rules must evolve to address new production methods and forms of evidence. Projects like this one provide the technical data needed to update them.

ABS Vice President of Technology Michael Kei said digital qualification has an important role in the adoption of additive manufacturing across the marine and offshore sectors. He said ABS aims to strengthen confidence in the technology by improving how qualification evidence is generated, evaluated and traced. Clear qualification routes will be essential if additively manufactured parts are to move from trials to wider use. For shipowners, that could mean faster access to replacement parts and less downtime.