Consolidated Stators Designed for Additive Manufacturing, with Optimized Internal Cooling Channels, Accelerate Lead-times, Reduce Costs and Improve Thermal Performance
500 mm
seamless direct metal parts
200:1
part count reduction demonstrated
1600 K
operating temperature achieved

Improve System Efficiency and Reliability

A 3D printed metal stator

The parts used in turbomachinery must withstand intense thermal and structural loads. The highest requirements for part-level performance are inside hot zones of turbomachinery and among this group are compressor and turbine stator vanes, and integrated stators. With 3D Systems’ Additive Manufacturing (AM) solutions, it is possible to reduce points of failure generated by traditional complex manufacturing assemblies by consolidating several parts into one, which improves yield and reliability, and reduces manufacturing labor.

To achieve maximum efficiency and reliability, critical gas turbine components require complex internal cooling channels that are difficult to machine. Our solutions allow for the creation of optimal conformal cooling that improves thermal performance.

The Benefits of Stator Production Using 3D Systems Additive Manufacturing Solutions

  • Stator Vanes 3D printed part

  • Reliability and Reduced Cost

    Traditional manufacturing of stator vanes and rings from billet is costly, especially with the tough materials used to make stator vanes. These complex shapes must then be brazed together when complete, further increasing costs and lead times while sacrificing assembly strength and longevity. Replacing multipart assemblies with monolithic parts increases reliability, improves manufacturing yield, and reduces labor costs.
  • a man standing inside of a 3D printed stator, showing that the scale is larger than him

  • Time to Market

    One of the traditional approaches to manufacturing stator vanes and other turbine components is through the decades-old process of investment casting technology and its use of wax patterns. However, making traditional patterns first requires a mold that is costly to machine and often takes weeks or even months to produce. Because stereolithography additive manufacturing technology can produce hollow sacrificial patterns literally overnight, engineers can reach an optimal design far more quickly and without tooling and storage costs compared to conventional manufacturing methods.
  • a 3d printed stator vanes part

  • Improve Thermal Performance

    Thanks to additive manufacturing’s ability to produce previously un-manufacturable parts and part features, engineers have the freedom to design optimized turbomachinery components. For example, enabling the creation of more complex cooling channels will significantly increase heat transfer and turbine efficiency.

Solving the Challenges of Stator Vane Design and Manufacturing

  • Decades of Experience

    3D Systems Application Innovation Group (AIG) guides customers from design concept to product production and technology transfer into scalable manufacturing. We offer full DfAM (Design for Additive Manufacturing) consultation services, which include optimization of component geometries, cost and production optimization, additive manufacture planning, and experience with a wide array of finishing and post-processing technologies.

  • Additive Manufacturing Solutions for Large Metal Parts

    With our broad range of advanced additive manufacturing technologies, materials, and software solutions, we can deliver seamless 3D printed metal parts of 500 x 500 x 450 mm within tight tolerances and with outstanding material properties. For investment casting of any superalloy, you can print patterns up to 1500 mm long.

  • Production Capability

    With our production facilities, we can be your agile manufacturing arm, helping you transition from prototype to production, while offering increased supply chain capacity and flexibility.

More Turbomachinery Applications

The engine of airplane

Combustor Components
A 3D printed Impeller made from Direct Metal Printing

Impellers
a 3D case rendering

Casings and Ducting

Resources

  • Vaupell Case Study 940x494

    The Digital Foundry

    Digital processes and new additive manufacturing technologies are poised to deliver massive time and cost savings: Production workflows that traditionally take weeks can now be done in hours.

    Download the White Paper
  • Metal 3D Printed DLR Fuel Injector

    Rethink Design and Manufacturing Processes

    Download this eBook to learn how to reduce total part count, streamline production and elevate part performance with metal additive manufacturing.

    Get the eBook

  • Design for Performance

    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.

    Get the Design Guide

Learn More About Turbomachinery Stator Vanes Manufacturing Solutions

Manufacture metal parts with scalable DMLS with removable build chamber for continuous printing

DMP Factory 500

Robust, high quality metal AM with integrated powder management

LaserForm Ni718 (A) DMP Combustion Chamber

LaserForm Ni718 (A)

Oxidation, corrosion and extremely high-temperature resistant

Highly accurate, humidity/moisture resistant, antimony-free casting patterns

Accura Fidelity (SLA)

Highly accurate, humidity/moisture resistant, antimony-free casting patterns

3D Systems 3DXpert hero image

3DXpert

All-in-One Integrated Software for Industrial Additive Manufacturing

3D Systems Laserform Ni625 Nozzle

LaserForm Ni625 (A)

Excellent corrosion resistance, high strength and heat resistance

3D Systems ProX 950 3D Printer (SLA) large-format 3D printing

ProX 950

All the benefits of SLA 3D printing in extra-large format

DMP Inspection for QA in Metal AM

DMP Inspection

Minimize secondary inspection in Metal AM with validated automated analysis

DMP Monitoring - real-time metal additive process monitoring

DMP Monitoring

Real-time process monitoring for informed decisions on product quality

3D Systems DMP Metal LaserForm Ti Gr23 (A) titanium alloy

LaserForm Ti Gr23 (A)

High strength, low weight, excellent biocompatibility - lower Oxygen than Gr5

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  • Application Innovation Group

    Our team can help you solve your most difficult design and production challenges with additive manufacturing solutions. Together we’ll identify your needs, working with you to optimize your designs, prototype, validate and define a manufacturing flow.
    Find out more