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Siemens Energy has long relied on additive manufacturing to reduce development times and build high-performance parts. The company now uses MakerVerse to expand its additive manufacturing capabilities for developing specialized end-use parts and unique prototypes.
Industry
Energy
Company location
Munich, Germany
Company size
90,000+
Use case
End-use parts, prototyping
Technology used
Laser Powder Bed Fusion, Stereolithography, Polyjet
Material used
Inconel 625, Accura ClearVue, and others
Parts produced
Emissions probes for a gas turbine and a cosmetic prototype model
Results
Gained access to new manufacturing technologies and materials with industrial quality
Impact
MakerVerse helped save weeks in time thanks to streamlined processes and short lead times.
Photo courtesy of Siemens Energy
Emissions probes for a gas turbine made from Inconel 625 using Laser Powder Bed Fusion. Welding and machining were used during production.
One of Siemens Energy's gas turbines. The turbines can weigh more than 100,000 kilograms.
Siemens Energy knows the benefits of additive manufacturing. As early adopters, additive manufacturing has supported the company to reduce development times by up to 75% and cut greenhouse gas emissions by 30% for its turbines. These tangible benefits made it a priority to increase additive manufacturing beyond the organization’s in-house capabilities.
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Using MakerVerse, Siemens Energy gained access and extended reach to supply chains with new technologies, materials, and expertise. MakerVerse's technology offering ranges from additive manufacturing to CNC machining.
One project was sophisticated emissions probes used for gas turbines. These complex end-use parts required additional machining and welding, all while following precise specifications. Additionally, MakerVerse helps Siemens Energy quickly bring prototypes to life with fast turnaround times.
"Working with MakerVerse and leveraging their extensive eco-system to support on demand parts requirements has allowed us to be more responsive and agile.
They have successfully delivered on what we have asked of them to date, and this allows us to focus our expertise on where it is most needed."
Quan Lac
Vice President of Additive Manufacturing at Siemens Energy
The challenges
Siemens Energy possesses extensive expertise to design and print additive parts. However, for rapid prototyping and access to the full range of materials, finishes, and different additive manufacturing technologies, they balance their in-house capabilities with a supporting supply chain strategy.
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A series of emissions probes were a perfect fit for this strategy. These gas turbine probes are used to measure emissions. Siemens Energy knew additive manufacturing was the best way to accelerate product development of these parts, with complex internal design to support the gas flow.
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Once printed, the probe required precision machining, and threaded gas connectors would to be welded on.
Siemens Energy sought a way to source prototypes quickly and easily from various technologies and materials from a one stop service.
Siemens Energy also sought a way to source prototypes quickly and easily from various technologies and materials from a one-stop service.
Cosmetic prototypes made with PolyJet. These prototypes demonstrate gas flows and temperatures.
The solutions
Instead of spending excessive time identifying, onboarding, and qualifying potential suppliers, MakerVerse offered a complete solution for a range of technologies and materials.
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By working with MakerVerse, Siemens Energy gained more than a mere fulfillment partner for its gas probes. They also received assistance with the production plan, design, and oversight. MakerVerse's team of engineering experts ensured the industrial quality of the gas probes through every step of the process.
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MakerVerse guaranteed that the advanced finishing, requiring both precision machining and welding. All of this followed exact specifications and was measured and documented according to industry standards.
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In addition to such sophisticated parts, Siemens Energy leverages MakerVerse for simpler prototypes that weren't possible in-house or require quick response.
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In these cases, reliable quotes and fast lead times proved essential. One such prototype was a colorful cosmetic prototype produced through PolyJet technology, which is a technology not commonly used by industrial companies due to limited applications. This prototype demonstrates what gas flows and temperatures look like within a part. Other applications include transparent gas turbine components which can highlight internal geometries.
PolyJet technology is only sometimes used by industrial companies due to limited applications, while leveraging stereolithography can be time-intensive due to the nature of the resins used. MakerVerse provided Siemens Energy access to both these technologies with limited effort and no capital expenditures required.
The results
Siemens Energy continues investing in its in-house capabilities, while at the same time working with partners like MakerVerse to access a more extensive eco-system of materials and technologies. The partnership with MakerVerse allows Siemens Energy to focus its own resources on the most critical projects, while quickly and reliably sourcing other parts.
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Whether it's a complex metal parts or fast prototypes from various materials, Siemens Energy saves time and money while innovating. "We are establishing a good foundation of extended manufacturing capability through MakerVerse," said Quan Lac, VP of Additive Manufacturing at Siemens Energy. " I look forward to the teams continuing to work closely together in the future to build on this."