New facility brings advanced WAAM capability closer to energy, defence and maritime customers, accelerating production of critical industrial components

DEEP Manufacturing, a specialist in Wire Arc Additive Manufacturing (WAAM) and hybrid manufacturing solutions, is expanding its U.S. operations with the launch of a new advanced manufacturing facility in Houston, bringing large-scale additive manufacturing capability closer to customers in the energy, defence and maritime sectors.

The facility will officially launch on May 6, when visitors will see examples of DEEP Manufacturing’s printing capability, including a mock-up of a pioneering new pressure-rated vessel set to be certified to DNV standards - a world first for WAAM. Additional WAAM-produced components manufactured in carbon steel and nickel-based alloys will also be on display, demonstrating the scale and flexibility of the company’s additive manufacturing capability.

The move strengthens domestic manufacturing capacity for high-integrity components at a time when global supply chains remain under pressure, enabling faster production and delivery of large, complex parts used in critical industrial infrastructure.

Houston is one of the world’s leading hubs for energy, subsea and industrial engineering, making it a strategic location for advanced manufacturing technologies supporting offshore, maritime and defence supply chains.

DEEP Manufacturing’s new 50,000 sq ft facility represents a major step in the company’s global expansion and forms part of a wider $10 million investment in U.S. advanced manufacturing capability planned by the end of 2026.

The Houston site will house four WAAM robotic systems at launch, with additional systems planned throughout the year, including capabilities for post-processing and inspection as the facility continues to scale.

The facility is already operational, with the team having completed its first prints ahead of full operational readiness in May.

The company currently employs 10 staff in Houston, with plans to grow the team to around 30 by the end of the year, reflecting both the pace of expansion and increasing customer demand.

Wire Arc Additive Manufacturing (WAAM) enables large metal components to be produced layer by layer using robotic welding systems. The technology allows manufacturers to produce complex, high-integrity structures significantly faster than traditional forging and casting methods, helping reduce lead times for critical industrial components.

The DEEP Manufacturing team in Houston mirrors the structure of the company’s Bristol facility in the UK, bringing together engineers, technicians and additive manufacturing specialists to operate the site’s robotic systems and support customers across multiple sectors.

The development of the Houston site has progressed rapidly, with the opening brought forward by a year into 2026. The first systems were delivered at the end of 2025, with two operational by January 2026. February focused on intensive training and knowledge transfer from the UK team, while March has centred on Inconel 625 deposition trials.

April will see the manipulators commissioned alongside ISO 9001 and DNV Approval of Manufacture audits ahead of the facility’s official launch.

Peter Richards, CEO of DEEP Manufacturing, said:
“Houston represents a major step in scaling industrial additive manufacturing in the United States. By bringing our WAAM capability closer to customers in energy, defence and maritime sectors, we can dramatically reduce lead times for large, high-integrity components while strengthening supply-chain resilience for critical industries.”

Supported by advanced facilities in Bristol, the Houston location will provide significant multidisciplinary engineering expertise, enabling customers to meet the demands of the most challenging environments at scale and with confidence.

KeyFacts Energy Industry Directory: DEEP Manufacturing