What is additive manufacturing and how does Siemens Energy utilize it?

Additive manufacturing, also known as 3D printing, is a process of creating objects by layering materials based on digital models. Siemens Energy uses this technology to rapidly prototype, repair, and produce high-performance components for turbines and compressors, enhancing efficiency and reducing production times.

What are the benefits of using additive manufacturing for energy sector components?

Additive manufacturing offers several advantages, including faster turnaround times, increased design flexibility, superior material efficiency, and the ability to produce complex geometries that are difficult to achieve with traditional manufacturing methods. These benefits help optimize operations and drive innovation in the energy sector.

What are the benefits of using additive manufacturing for other sectors components?

Additive manufacturing offers other sectors benefits like increased design freedom for complex geometries, reduced material waste, and the ability to produce customized parts on demand. It also accelerates prototyping and can consolidate multiple components into a single part, leading to lighter and more efficient designs.

Additive Manufacturing

Metallic swirler components with conical shapes and internal structures, arranged on a platform and produced by Laser Powder Bed Fusion (LPBF)

At Siemens Energy, we're at the forefront of Additive Manufacturing (AM), completely revolutionizing how we design, produce, and even repair industrial components. We utilize sophisticated 3D printing technologies like Laser Powder Bed Fusion (LPBF) and Wire Arc Additive Manufacturing (WAAM) to develop high-performance parts, facilitate rapid prototyping, and offer on-demand spare parts. This significantly cuts down on both lead times and material waste. Our expertise also extends to advanced engineering services, including the design, simulation, and qualification of AM components. We've built this knowledge on over a decade of experience and millions of operating hours of AM parts within our own gas turbine fleet.

Technician in a white protective suit and full-face respirator operating machinery in a cleanroom, holding a component while wearing blue gloves.

Person holding a 3D-printed part in front of a computer screen displaying its CAD model, with a second monitor and cables on a wooden desk.

Laser Powder Bed Fusion (LPBF) Additive Manufacturing process with multiple lasers fusing powdered material on a flat bed

At Siemens Energy, we've been at the forefront of industrializing additive manufacturing, for the high-performance components of our gas turbines. We started our efforts around 2008, establishing specialized competence centers like our facility in Finspång, Sweden which allowed us to push the boundaries of design freedom and functional integration. A significant milestone for us was in 2017 when we successfully engine-tested 3D-printed gas turbine blades under full-load conditions. Today, our AM capabilities go beyond prototyping; we're actively engaged in serial production of complex parts like burner nozzles and turbine vanes, which have drastically improved lead times and provided previously unattainable levels of performance. We use advanced repair and upgrade solutions for power generation assets to reduce scrap and increase the sustainability of our parts.

Since 2006 our Materials Solutions business has served various customers in aerospace, energy, motorsport, and defense industries. In 2016 Materials Solutions joined Siemens Energy and we continue to help our customers develop and manufacture championship level performing additive components wherever they are needed.

•Advanced post-processing capabilities: Heat treatments, conventional and non-conventional machining, welding, brazing, coatings, and more.

•Industrialized AM production: With over a decade of expertise and a million+ part operating hours.

•Integrated design-to-print-to-part solutions: For full-lifecycle services, including DfAM optimization and serial production.

•Accelerated AM adoption: Through advanced training, rapid prototyping, and high-performance component innovation.

•Certified supplier: ISO9001, AS9100, ITAR Registration, NadCap, AMS7003

Siemens Energy additive manufacturing accelerates the innovation cycle for industries like aerospace, power generation, oil & gas, and automotive through advanced prototyping. We enable engineers to swiftly create and rigorously evaluate new part designs, allowing for rapid iteration and refinement of concepts in record time. By quickly transforming digital models into physical prototypes, we empower faster design verification and testing, significantly shortening product development timelines and ensuring that solutions are optimized for performance and reliability before committing to full-scale production.

Operator using a touchscreen on an EOS 3D printer displaying a digital layout with curved shapes and angles, including values like 94.27° and 266.32°

Additive Manufacturing revolutionizes asset longevity and operational efficiency through advanced repair solutions for critical components in industries like power generation, oil & gas, and industrial manufacturing. Utilizing sophisticated additive repair techniques, we can precisely rebuild worn or damaged parts, extend their service life and significantly reduce the need for costly replacements. This capability minimizes downtime, optimizes maintenance schedules, and enhances the sustainability of high-value industrial assets, ensuring continued reliable operation in challenging environments.

hree circular insets illustrating Additive Manufacturing Repair Technologies, featuring detailed metallic parts and industrial machine components on a dark purple background.

We offer comprehensive additive manufacturing capabilities for high-performance component production across demanding sectors such as power generation, aerospace, performance automotive, industrial, and defense. Leveraging advanced metal additive processes like Laser Powder Bed Fusion and Wire Arc, we produce materials with superior strength and productivity through optimized build parameters. Our quality assurance and post-processing ensure that every manufactured part meets the standards required for critical applications, from turbomachinery components to specialized tooling.

Close-up of a 3D printer performing laser sintering, with a bright laser fusing powdered material into complex circular and curved geometries.

For sectors heavily reliant on operational continuity such as power generation, aerospace, and industrial applications, Siemens Energy additive manufacturing provides agile "spare parts on demand" services. This capability drastically reduces lead times for critical spares, eliminates the need for extensive physical inventories, and mitigates supply chain disruptions. By leveraging digital blueprints and additive manufacturing, we can produce high-quality, certified replacement parts precisely when and where they are needed, ensuring maximal uptime and operational resilience for even legacy equipment.

Close-up of hands holding two 3D printed parts of a metallic cylindrical component, showing internal holes and structural supports in focus.

Powder bed fusion

Powder bed fusion is an advanced additive manufacturing process that uses a heat source, such as a laser or electron beam, to selectively melt and fuse powdered material layer by layer, creating a solid 3D object. This technique can produce complex geometries with high precision and is used for metal parts. PBF includes various methods like Direct Metal Laser Sintering (DMLS) and Electron Beam Melting (EBM) utilizing different energy sources to achieve fusion.

Close-up of an industrial 3D printing bed with multiple circular parts being additively manufactured, showing intricate patterns in progress.

Wire arc additive manufacturing

Wire arc additive manufacturing is an advanced 3D printing technique that combines Gas Metal Arc Welding (GMAW) with advanced robotics to create large, complex metal parts. Using an electric arc to melt and deposit metal wire layer by layer, WAAM is known for high deposition rates, cost-effectiveness, and the ability to produce parts over a cubic meter in size. It offers reduced material waste, lower startup costs, and the capability to manufacture parts with complex geometries and multiple materials, making it ideal for engineering structures and component repairs.

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