Additive Manufacturing (AM) is ushering in a new era for the maritime industry as Wärtsilä partners with Nikon SLM Solutions, nTopology, and Oqton to create an advanced impeller with reduced weight and superior performance.
Discover how metal 3D printing is revolutionizing the maritime sector through this groundbreaking collaboration, setting new standards for component design and manufacturing.
Introduction
Wärtsilä, a leader in energy and maritime industries, needed to develop an optimized impeller with exceptional performance. After 500 hours of testing under extreme conditions, the results are clear: a lighter, more efficient solution with the potential to unlock new business opportunities.
Final impeller after multiple demos
Industry Challenges
Impellers are essential components in pumping systems for fluid transport in the energy sector. Due to varying needs, impellers must often be customized. To ensure continuous operation, companies produce them in large quantities and keep them in stock, as manufacturing a new part can take up to 20 weeks. This practice increases storage costs and results in excess inventory.
Solution: Additive Manufacturing (AM)
With metal 3D printing, components can be produced on demand, minimizing overproduction and storage costs. AM also shortens lead times, enhances part performance, and enables the storage of designs digitally. Furthermore, it opens the door to new business models by eliminating the need for casting molds, saving thousands of euros in tooling costs.
Collaboration Process
To develop the advanced impeller, Wärtsilä teamed up with three technology partners:
🔹 Nikon SLM Solutions – Experts in metal 3D printing solutions.
🔹 nTopology – Providers of advanced design optimization software.
🔹 Oqton – Specialists in production simulation with their Amphyon software.
This collaboration resulted in an innovative solution, unlocking new application possibilities.
Successful partnership between Wärtsilä, nTopology, Oqton, and Nikon SLM Solutions
Application of the Impeller in the Maritime Industry
The project began by redesigning the impeller to reduce weight without compromising durability. nTopology provided advanced tools to optimize the design using lattice structures, ensuring performance while minimizing mass. The impeller was printed on an SLM®280 PS, and its model was fine-tuned using Amphyon to achieve high precision.
The impeller underwent rigorous lab testing at temperatures of 120°C and rotational speeds of 2,600 rpm over 500 hours. The tests revealed no signs of damage or wear, confirming the superior quality of the material used.
Part 1: Cross-section of the second iteration (lightweight design) with a 40% weight reduction.
Part 2: Cross-section of the first iteration (heavy design) with a 5% weight reduction.
Part 3: Picture of the tested impeller (heavy design) with a 5% weight reduction after 500 hours of testing on a full-scale Wärtsilä lab engine.
Explore the SLM 3D Printer line HERE
Read more about Lattice structure: Materialise 3-matic – The Optimal Solution for Lattice Structure in 3D
Advanced Technologies Used
❇ nTopology Software:
- Creates lattice structures aligned with the impeller’s rotational axis for improved balance.
- Analyzes stress levels to adjust lattice beam thickness, reducing weight while maintaining strength.
❇ Free Float Technology from Nikon SLM Solutions:
- Enables printing surfaces with angles as low as 20 degrees without support structures, minimizing material use and post-processing time.
- Particularly beneficial for complex components like impellers, where support removal is challenging.
❇ IN718 Alloy:
- A nickel-based alloy known for its heat resistance and corrosion protection, widely used in turbines, aerospace, and energy applications.
- Maintains strength even under high temperatures and pressures, making it ideal for demanding environments.
Key Results
🔹 5% weight reduction achieved in the first model (IMP1) and 40% in the second (IMP2).
🔹 500 hours of real-world testing with no signs of wear or defects.
🔹 Optimized model achieved dimensional accuracy with deviations below 400µm.
🔹 Production time reduced by eliminating casting molds and minimizing support structures.
Testimonials
“This project highlights the power of sharing top-tier expertise across companies working toward a common goal. The impeller has introduced several technical innovations and added value to marine engines. We created a lightweight component that was beyond our expectations, sparking potential for more AM applications in the maritime sector.” — Francesco Trevisan, Wärtsilä
“Nikon SLM Solutions and Wärtsilä have enjoyed a long-standing partnership to create innovative components for the energy sector using advanced AM technology. This project is among the first to leverage these capabilities for complex impeller designs. With this technology, we can now print challenging rotating parts, significantly reducing manufacturing lead times and post-processing costs.” — Fabrizio Ragusa, Nikon SLM Solutions
“We have achieved a lightweight component that we never thought possible. This application paves the way for more AM solutions in the maritime industry.” — Juho Raukola, Wärtsilä
“Thanks to the combined knowledge of the four companies, we’ve developed a solution that elevates AM in the energy sector. The integration of cutting-edge design tools, pre-deformation simulations, and advanced production resulted in a part that excels in every aspect. Reduced weight, enhanced performance, and a production time of just days — all in one component.” — Lorenz Kropholler, Nikon SLM Solutions
“Free Float is a game-changer, enabling stunning designs while maximizing AM’s weight-saving potential. It has been validated by a demanding end-user and demonstrates the capabilities of the most advanced mid-size multi-laser metal AM machine available.” — Benjamin Haas, Nikon SLM Solution
Future Potential and Impact
This advanced impeller not only improves Wärtsilä’s operational efficiency but also unlocks new business opportunities in spare parts manufacturing. By combining AM with digital tools, companies can meet market demands without the need for large inventories.
The collaboration showcases the vast potential of metal 3D printing for developing optimized solutions in the energy and maritime sectors. With state-of-the-art technology from Nikon SLM Solutions, nTopology, and Oqton, Wärtsilä solidifies its position as a leader in manufacturing innovation.
Conclusion
This project demonstrates the transformative power of additive manufacturing and cross-industry collaboration. Through metal 3D printing, businesses can optimize production processes and explore new avenues in product development and services. Wärtsilä and its partners have created an impeller that is lighter, more efficient, and enhances competitiveness in the maritime industry.
Source: Nikon SLM Solutions Resources
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