This 97 kg steam-turbine spare component for TotalEnergies was produced by MX3D using robotic Wire Arc Additive Manufacturing (WAAM). The full-scale part was built in just five days of continuous printing at MX3D’s Amsterdam facility and is now ready for installation back into service.
“Using WAAM plus reverse engineering allowed us to deliver a fully certified replacement part in a fraction of the time of a new casting, without compromising on integrity.”
– Kevin Affari | MX3D WAAM Engineer
Traditionally, this part is cast with long lead times and limited flexibility for geometry changes. By combining 3D scanning, material characterization, and CAD reconstruction, MX3D recreated the complex geometry of the original component while matching the alloy’s mechanical performance. The WAAM build was executed with MX3D’s proprietary MetalXL software to plan toolpaths, deposition strategy, and real-time monitoring, ensuring consistent quality throughout the five-day print.
After printing, the component underwent milling to the final geometry, reducing its weight from 120 kg to 97 kg. Non-destructive testing, including radiographic, penetrant, and visual inspections, and a witnessed hydrostatic pressure test, confirmed its structural integrity under operating conditions. Full traceability and certification were provided for safe reinstallation.
This project demonstrates how large, safety-critical components for the energy sector can be reverse-engineered and produced using MX3D’s robotic WAAM technology in a fraction of the lead time required for traditional casting.
Specifications
- Part: Steam turbine spare component
- Material: ER70SG / matching original cast alloy properties
- Dimensions: 780 mm (L) × 360 mm (W) × 540 mm (H)
- Weight: 120 kg before machining; 97 kg after machining
- Printing Time: 5 days continuous WAAM production
- Client: Totalenergies
