GE has launched a research partnership to develop the world’s largest 3D printer to streamline the production of key components of GE’s Haliade-X offshore wind turbine.
GE is working with Fraunhofer IGCV and Voxeljet on the Advance Casting Cell (ACC) 3D printer project.
The project will benefit from financial support from the German Federal Ministry for Economic Affairs and Energy.
The ACC 3D printer will be capable of printing moulds to cast components for the nacelle of the GE Haliade-X that can each weigh more than 60 metric tonnes, reducing the time it takes to produce this pattern and mould from around 10 weeks to two weeks.
In addition, the use of the 3D printer is expected to reduce the product’s carbon footprint by eliminating the need to transport the large parts from a central manufacturing location.
The partners expect to launch the project during the third quarter of 2021 with initial printer trials starting during the first quarter of 2022.
The project involves the development of a new, large format 3D printer capable of producing sand moulds for casting the highly complex metal parts of different shapes and sizes that make up an offshore wind turbine nacelle.
The modular 3D printing process, which is based on Voxeljet’s core “Binder-Jetting” technology, can be configured to print moulds for castings up to 9.5 metres in diameter and 60-plus tonnes.
Juan Pablo Cilia, senior additive design engineer at GE Renewable Energy, said: “The 3D printed moulds will bring many benefits including improved casting quality through improved surface finish, part accuracy and consistency.
“Furthermore, sand binder jet moulds or additive moulds provide cost savings by reducing machining time and other material costs due to optimized design.
“This unprecedented production technology will be a game changer for production efficiency allowing localised manufacturing in high cost countries, a key benefit for our customers looking to maximise the local economic development benefits of offshore wind.”
Voxeljet CEO Ingo Ederer added: “While offsite on-demand 3D printing provides many benefits for small quantities of cast parts, running a 3D printing system on-site leverages the technology to its fullest capacity.
“Given the demand for offshore wind turbines, that will help a lot to fulfil project schedules and high market demands.
“It is our mission to bring 3D printing into true industrial manufacturing and we are therefore very excited to be part of this groundbreaking project.”