Minimize Downtime, Improve Supply Chain Efficiency, and Lower Costs with Our Additive Manufacturing Solutions and Services
material waste reduction
reduction in part count
faster component delivery
Develop and Deploy Energy-Efficient Turbomachinery Components Faster and More Cost-Effectively
Gas turbine firing animation with compressor and power turbine
The turbomachinery industry is not only highly competitive but faces calls from the marketplace for increased fuel efficiency, lower maintenance costs, and reduced greenhouse gases. With that comes the need for shorter design cycles along with an unrelenting demand for high-quality, reliable, and high-performance components that meet or exceed design criteria.
Given 3D Systems' extensive experience in turbomachinery and turbine components development and manufacturing, helping customers meet these goals is one of our top priorities. Our team stands ready to guide OEMs and suppliers through design optimization and rapid manufacturing deployment and will see your company achieve lasting success in this high-tech, fast-paced industry.
Additive Manufacturing Applications for Turbomachinery
Fuel injectors, mixers, and other combustor components have intricate geometries that are both difficult and costly to produce using conventional methods. Additive manufacturing changes this equation by enabling the realization of functionally optimized designs and reducing the need for multi-part assemblies. Designers can consolidate and produce high-end turbine parts, with advanced materials while increasing overall efficiency.
As with many of the components found inside turbomachinery, compressor and turbine stator vanes, and integrated stators endure intense thermal and structural loads. Consolidating multiple part assemblies into a single part increases manufacturing yield and component reliability, while the integration of highly efficient cooling channels improves thermal performance.
Fuel efficiency and equipment life are top on the list of turbomachinery requirements. By using additive solutions for impeller manufacturing, new levels of machinery performance can be unlocked through improving design features and leveraging extreme temperature-resistant materials. All of this can be accomplished while reducing manufacturing costs and eliminating the need for expensive, long lead-time tooling and 5-axis machining.
Proper exhaust gas evacuation is just as important to gas turbine efficiency as a generous supply of intake air. Both are achieved through ducting that may be relatively unique across installations based on customer site requirements. Additionally, high-strength turbomachinery enclosures are a mix of very large part sizes, specialized materials, and functionally efficient complex features. Creating and maintaining physical tooling for these applications is costly and time-consuming, and a tool-less approach allows for customization per installation requirements. Here again, additive manufacturing simplifies prototyping and production with highly accurate casting patterns.
The 3D Systems Application Innovation Group (AIG) leverages its decades of additive manufacturing expertise to help OEMs and suppliers develop optimized solutions for their applications. By utilizing a "design for additive manufacturing” (DFaM) approach, you can quickly develop and produce parts that consistently meet or exceed industry requirements.
Large Metal Parts with Additive Manufacturing Solutions
Our hardware, software, and materials offer customers unprecedented design flexibility, economics, and product reliability that is unmatched by any subtractive manufacturing method. From the production of intricate direct metal printed parts to extra-large, lightweight, antimony-free patterns for precision investment casting, we can meet your turbomachinery needs.
With our production facilities, we can be your agile manufacturing arm, helping you transition smoothly from prototype to production, while offering increased supply chain capacity and flexibility.
From installation, hands-on training and consulting support, and 3D Systems’ ability to develop pre-qualified manufacturing processes for our customers’ critical parts, turbomachinery OEM manufacturers and turbine parts suppliers are quickly able to reach production volumes on their own to reduce costs and accelerate delivery times. Our dedicated team works with you across every step, from pre-production to full-scale volume production.
How 3D Systems Helps Manufacturers Gain a Competitive Advantage
With complex, accurate, extra-large investment casting patterns and direct metal 3D printed components that were previously unthinkable to produce, features such as conformal cooling channels, novel gas and fluid flow, and consolidated part assemblies can be optimally designed for the highest efficiency and reliability.
Performance and Economics
Through component consolidation, greater thermal efficiency, and streamlined supply chain, additive manufacturing can help increase reliability and uptime, reduce maintenance costs, improve fuel efficiency, and lead to increased power generation.
Faster Time to Market
With Direct Metal Printing, tool-free investment casting patterns, and 3D Systems’ manufacturing capabilities, manufacturers can reduce the time between design iterations, enabling rapid time to market.. Post-installation, these capabilities can also be used to produce maintenance repair overhaul (MRO) parts to help reduce inventory and increase customer satisfaction.
Broad Expertise and Capability
With Direct Metal Printing technology and stereolithography for investment casting patterns, 3D Systems is your experienced consulting partner to establish advanced additive manufacturing capabilities with all the benefits of “designed for additive manufacturing” components.
Scalability and Flexibility
Between our expert teams, manufacturing facilities, equipment, software, and materials, 3D Systems helps industrial gas turbine manufacturers and suppliers scale up to reduce costs, boost performance, and accelerate delivery through each stage of a product’s lifecycle.
Optimizing Fluid Flows with Additive Manufacturing
Find out how additive manufacturing resolves issues of traditionally manufactured turbine components by removing assembly operations, taking out excess weight, and enabling the production of more organic shapes.
Design, test and produce metal parts with 3D printing that are simply not possible with standard manufacturing. Create lightweight, high-strength structures and deliver new capabilities. Read the Metal Printing Design Guide to gain invaluable insight.