Caracol, a provider of large-format additive manufacturing (LFAM), has introduced Vipra AM, a large-scale metal parts manufacturing platform. Caraco aims to help manufacturers produce advanced large-scale industrial parts efficiently and sustainably.

Vipra AM is a robotic large-scale direct energy deposition (DeD) platform that leverages wire arc additive manufacturing processes that have been integrated into a hardware, software, and automation proprietary turnkey system.

The platform was created to maximize flexibility, control, and performance, expanding LFAM’s 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,” said Francesco De Stefano, CEO of Caracol AM.

With Vipra AM, Caracol has expanded its metal AM process control and software for large-format AM with thermoplastics and composites materials. “We developed a proprietary cutting-edge metal platform that combines state-of-the-art hardware and software with advanced robotic monitoring and automation,” said Stefano. “We want to enlarge the possibilities of industrial manufacturers to produce their most complex large-scale projects.”

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According to Stefano, Caracol spent years developing projects and scaling parts production with Vipra AM to develop a platform that can target specific needs and applications.

Caracol has unveiled two new configurations of Vipra:

• Vipra XQ (extreme quality) leverages plasma arc deposition technology to produce extremely high-quality components with exceptional finishing and precision. It is best suited for applications that require superior strength and precision, and can process an incredibly broad range of metals, including – stainless steels and titanium alloys. Caracol noted the system is ideal for large-scale, high-strength, high-integrity parts for sectors such as aerospace (e.g. load-bearing brackets and structural components) and energy (e.g. valves, gauges and structural piping connectors).

• Vipra XP (extreme productivity) is focused on maximizing productivity, minimizing operating costs in the manufacturing process of complex large scale metal projects. Caracol noted that its throughput combined with its ability to print also aluminum and nickel-based materials, make the system ideal for parts where lead times and lightweight are critical, such as transportation industries (e.g. automotive components, aerospace pressure vessels, marine propellers) and lower-end architectural applications (e.g. sculptures, lightweight organic structures).

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In both of its product configurations, Vipra AM was built to produce advanced applications such as load bearing finished parts, lightweight structures, high-temperature and 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," said 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.”

Caracol noted that Vipra AM offers capabilities that complement existing processes, enabling hybrid production models that combine legacy techniques with advanced metal deposition to help manufacturers optimize production lines, reduce waste, accelerate lead times, and drive overall efficiency without overhauling entire operations.