WAAM FOR ENERGY

Wire Arc Additive Manufacturing (WAAM) is the most promising 3D metal printing technology for manufacturing medium (>25kg) to large custom metal components (>25ton).  WAAM has a high material efficiency (up to 80%) and strongly reduced lead times.

WAAM FOR ENERGY

Wire Arc Additive Manufacturing (WAAM) is the most promising 3D metal printing technology for manufacturing medium (>25kg) to large custom metal components (>25ton).  WAAM has a high material efficiency (up to 80%) and strongly reduced lead times.

ENERGY

INDUSTRY VALUE

Operators in oil, gas, nuclear, hydro and wind energy hold large stock to cut downtime and reduce costs for the ‘last-minute’ manufacturing of critical parts. WAAM technology allows you to slash lead times and expenses. MX3D’s WAAM helps to reduce inventories and disruptions, speed up spare part manufacturing and enables on-site production.

ENERGY

INDUSTRY VALUE

Operators in oil, gas, nuclear, hydro and wind energy hold large stock to cut downtime and reduce costs for the ‘last-minute’ manufacturing of critical parts. WAAM technology allows you to slash lead times and expenses. MX3D’s WAAM helps to reduce inventories and disruptions, speed up spare part manufacturing and enables on-site production.

KEY BENEFITS

INCREASE SUPPLY CHAIN FLEXIBILITY

Reduce dependency on 1 supplier and purchase costs. Boost on site production capability. 

LOWERING INVENTORY COSTS

Reduce part count and volume. Lower minimum order quantity. Digital inventory.

REDUCE DOWNTIME

Shorter lead time. Extend equipment life cycle by increased quality or repair of legacy parts
INDUSTRY APPLICATION

IMPELLER

MX3D is an expert in printing NiBrAl (CuAl8Ni2) and SS316 impellers and propellers with WAAM.

The ability to print parts locally, fast and fully automated helps to solve critical supply chain problems. Customer such as ENGIE for the shown NiBrAl impeller, regain control over urgently needed parts and can reduce their stock volume. 

We succeeded in reducing a year+ conventional casting/milling route to a <60-day fully finished delivery. We also increased the quality of the part, where the difference between the cast (<95% density) and WAAM printed (99,9% density) says it all.

INDUSTRY APPLICATION

IMPELLER

MX3D is an expert in printing NiBrAl (CuAl8Ni2) and SS316 impellers and propellers with WAAM.

The ability to print parts locally, fast and fully automated helps to solve critical supply chain problems. Customer such as ENGIE for the shown NiBrAl impeller, regain control over urgently needed parts and can reduce their stock volume. 

We succeeded in reducing a year+ conventional casting/milling route to a <60-day fully finished delivery. We also increased the quality of the part, where the difference between the cast (<95% density) and WAAM printed (99,9% density) says it all.

INDUSTRY APPLICATION

WAAM CLAMP

Hybrid Wire Arc AM for the Oil & Gas Industry
This pipeline clamp is a great example of Hybrid WAAM, where MX3D incorporated pre-manufactured standard components into the WAAM process.

The WAAM Clamp is made and tested in collaboration with TEAM Industries and TiaT, two companies with extensive experience in the maintenance, testing and (emergency) repair of complex industrial pipe systems. The Belgian Welding Institute (BWI) handled the material testing and Lloyd’s Register (LRQA) supported MX3D on the certification process.

INDUSTRY APPLICATION

WAAM CLAMP

Hybrid Wire Arc AM for the Oil & Gas Industry
This pipeline clamp is a great example of Hybrid WAAM, where MX3D incorporated pre-manufactured standard components into the WAAM process.

The WAAM Clamp is made and tested in collaboration with TEAM Industries and TiaT, two companies with extensive experience in the maintenance, testing and (emergency) repair of complex industrial pipe systems. The Belgian Welding Institute (BWI) handled the material testing and Lloyd’s Register (LRQA) supported MX3D on the certification process.

heat-vent-mx3d
INDUSTRY APPLICATION

HEAT SINK

Transferring heat is key to the energy industry, as heat exchangers and sinks are customized to the specific location. With our WAAM technology, the customer has design freedom to design a part with optimal heat transfer within the design space. Also internal cooling channels can be introduced, which would normally not be possible to make with traditional methods.  .

This heat sink has been printed in 4mm stainless steel 316L. As a wide selection of materials is available, the part can be made in most of the more exotic alloys, which would not always be available as a block for milling.

INDUSTRY APPLICATION

HEAT SINK

Transferring heat is key to the energy industry, as heat exchangers and sinks are customized to the specific location. With our WAAM technology, the customer has design freedom to design a part with optimal heat transfer within the design space. Also internal cooling channels can be introduced, which would normally not be possible to make with traditional methods.  .

This heat sink has been printed in 4mm stainless steel 316L. As a wide selection of materials is available, the part can be made in most of the more exotic alloys, which would not always be available as a block for milling.

heat-vent-mx3d
INDUSTRY APPLICATION

FLANGES

MX3D’s M1 Metal AM System allows for 24/7 manufacturing to manufacture parts that needed to be outsourced to a casting or forging company before, resulting in significant lead time advantages

Valves and flanges are made using WAAM, due to the excellent material properties. With 3+ Kg/hr, flanges of 100Kg can be manufactured and finished in two days.

bronze-flange-oil-gas-mx3d
INDUSTRY APPLICATION

FLANGES

MX3D’s M1 Metal AM System allows for 24/7 manufacturing to manufacture parts that needed to be outsourced to a casting or forging company before, resulting in significant lead time advantages

Valves and flanges are made using WAAM, due to the excellent material properties. With 3+ Kg/hr, flanges of 100Kg can be manufactured and finished in two days.

bronze-flange-oil-gas-mx3d

CERTIFICATION & QUALIFICATION

 
OPTIMISATION OF PIPING COMPONENTS

USE CASE

JGC Corporation has announced that it will optimise construction methods through the introduction of 3D printers and construction automation. Under these circumstances, they have designed and printed a product using MX3D’s WAAM Technology using carbon steel and achieved results in application verification for full-scale introduction of metal 3D  printers with the same level of quality as conventional manufacturing methods.

In addition, they have printed unique parts using WAAM, and have achieved the results such as successfully printing lightweight and strong piping-related parts.

QUALIFICATION

QUALIFIED SYSTEM

MX3D produces parts with constant mechanical properties comparable to those of cast or wrought material. MX3D follows the available standards, like API20S, that apply to Metal 3D printing for the Energy Sector. We work closely with  Lloyd’s Register (LRQA), The Welding Institute (TWI), DNV GL, and Bureau Veritas to qualify our parts and machines. The services we provide are:

  • Set up and qualify Deposition Parameter Sets (DPS’s) for 3.1/ 3.2 certificate welding wires
  • Material characterisation and qualification (external certified supplier)
QUALIFICATION

QUALIFIED SYSTEM

MX3D produces parts with constant mechanical properties comparable to those of cast or wrought material. MX3D follows the available standards, like API20S, that apply to Metal 3D printing for the Energy Sector. We work closely with  Lloyd’s Register (LRQA), The Welding Institute (TWI), DNV GL, and Bureau Veritas to qualify our parts and machines. The services we provide are:

  • Set up and qualify Deposition Parameter Sets (DPS’s) for 3.1/ 3.2 certificate welding wires
  • Material characterisation and qualification (external certified supplier)

PARTNERS & CLIENTS

filippo-mx3d

Filippo Gilardi

GET IN TOUCH

Interested in our capabilities in the energy industry?
Contact our industry expert and we will get back to you!

GET IN TOUCH

Interested in our capabilities in the energy industry?
Contact our industry expert and we will get back to you!

filippo-mx3d

Filippo Gilardi

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