Case Study

How Large-Scale 3D Metal Printing Technology Prevented a $1T Infrastructure Crisis

Discover how Lincoln Electric’s large-scale 3D metal printing helped restore critical infrastructure in record time, cutting lead times by 84% and preventing a potential $1T economic disruption. Learn how additive manufacturing enabled faster production, improved performance, and new possibilities for large-scale civil works components.

What You’ll Learn

Preventing a $1T Economic Disruption: See how Lincoln Electric helped avert a potential $1.1 trillion GDP impact by restoring critical infrastructure at the Soo Locks ahead of schedule.
Challenges of Aging Infrastructure: Learn how a 60-year-old, highly specialized component failure exposed the risks of long lead times and limited sourcing options for large, custom parts.
Speed Advantage of Large-Scale 3D Printing: Discover how wire-arc additive manufacturing (WAAM) reduced production time from 18 months to just 3 months—an 84% lead time reduction.
Manufacturing at Massive Scale: Explore how Lincoln Electric produced a nearly 14-foot, 6,000+ lb component—the largest U.S. civil works part ever 3D printed.
End-to-End Production Expertise: Understand the full workflow—from printing and 3D scanning to CNC machining, precision welding, and final inspection—ensuring structural integrity and performance.
Enhanced Strength and Performance: Learn how the 3D-printed lever arm achieved 20–30% greater strength than traditional cast components while meeting extreme operational demands.
Proven Impact for Critical Infrastructure: See how this project sets a precedent for using additive manufacturing in large-scale civil works, signaling a shift in how complex, mission-critical components are produced.