The Wartsila Additive Manufacturing Center WHAM is now using 3D printing to create critical metal parts for the Wartsila engine, which has been successfully tested at full power. The work was completed in cooperation with the global engineering company Etteplan. The success of the test clearly shows that 3D printing is ready and can be widely used in the marine industry.
"We are confident enough to put the parts into the engine, and the result is self-evident-the engine always tells the truth," said Andreas Hjort, general manager of Smart Design. "The design freedom of 3D printing provides many value-added opportunities for new products and improving the performance of existing products."
The 3D leader of the future
Wartsila STH Manufacturing Excellence Director Giuseppe Saragò explained: “This project proves the powerful role of network thinking and ecosystem approach.” “Resources from different countries, 3D printer assets in our network-Finland’s EOS, Sweden’s AMEXCI and Italy’s Partners such as Additive FVG- and Etteplan have different roles and participation in all stages of the journey, but we are all committed to the ultimate goal. Transparency is crucial, and cooperation with the network allows us to use 3D printing Achieve a leap forward.
This work has also led to some interesting and innovative new research and development projects, which will once again benefit from our network, which connects several universities in Europe, partners such as Etteplan, and our internal resources together, so that Share expertise within the company and at the ecosystem level. "
In addition to multinational cooperation, Etteplan and Wrtsil are both part of a new industrial ecosystem, dedicated to bringing together Finnish companies in the 3D printing field. The Finnish Additive Manufacturing Ecosystem (FAME) is composed of more than 20 companies as founding members, and aims to support Finland's trajectory as a world leader in 3D printing utilization, sales and expertise, with 5% of the global printing market by 2030.
"Increasing 3D printing will reduce energy consumption and emissions, and enable global manufacturing to develop in a more sustainable direction," Raukola said. "WHAM has been at the forefront of this trend, and our goal is to continue to provide customers with ground-breaking custom 3D printed parts to save costs, reduce delivery times and eliminate storage and transportation requirements. If it sounds like you can To benefit from it, please feel free to contact us."
Leading the 3D trend
WHAM has been using 3D printing on a small scale for many years, making it a pioneer in 3D printing trends in the marine industry. The team is equipped with plastic, carbon and metal printers in its facilities, available to anyone in the company who can use them, thereby expanding the potential for innovation.
Recognizing the wide range of opportunities provided by 3D printing, WHAM began to collaborate with local universities to develop regional ecosystems in 2018. Through this cooperation, a series of lectures and visits were conducted, introducing basic 3D printing technology to students, stimulating the enthusiasm of undergraduates, and aiming to bring new talents and development to the industry. The long-term goal is to build Vaasa, where most of Wartsila's engines are designed, into a world-class 3D printing center, combining industry skills with new academic achievements.
Technologies that possess 3D printing expertise and engine design expertise are also expected to accelerate innovation. Wartsila innovation expert Juho Raukola said: “When you are looking for new engine components and trying to figure out whether 3D metal printing can be used, you can go next door and go beyond everything.” explained.
WHAM`s first significant success was in 2019, when it redesigned the composite lifting gear for heavy engine parts in 3D. Traditionally, lifting gear is made of solid steel, which is expensive and time-consuming to operate, not to mention cumbersome and difficult to transport. Hjort pointed out: “There is doubt on the market whether 3D printing can produce components that are strong enough to meet the strength of heavy-duty engine parts, but our research and testing have proved that this material is indeed doubtful. It is not an obstacle – in fact, 3D printing provides Opportunities are far from limiting."
The new 3D printed lifting tools are lighter, more compact and easier to use-and can save up to 100,000 euros in tool costs. It also performed very well, lifting a 240 kg engine piston for the first time and providing an astonishing maximum capacity of 960 kg without deformation. The test was carried out with the help of Bureau Veritas, an international certification body, which made it the world's first 3D printed CE certified lifting tool. Local production of tools replaces logistics chains and factory production, thereby reducing waste and pollution, and eliminating the waiting time for tools manufactured by third-party suppliers.