Cost competitive 3D printed metal component

Sandvik presented Etteplan with a challenge: to optimize and redesign a Geneva drive rotator piece for metal additive manufacturing, also known as metal 3D printing, for a price that is competitive with traditional manufacturing.


The project goals included producing a feasible, interchangeable solution that is lightweight and has low cost. This same part had been optimized by a thesis worker hired by Sandvik previously, resulting in a design that was 72% lighter than the original but also 300% more expensive.

Sandvik entrusted the project to Etteplan, who has in the last years invested heavily in competence development for additive manufacturing design and in the deployment of superior simulation tools for material optimization.

Etteplan rotator piece 3d printing Sandvik-3d-printed-piece.pngSandvik2.png

Figure 1. Sandvik’s Geneva drive traditionally manufactured rotator piece (top & bottom left) and an AM redesign for the piece conducted by a Sandvik

Download the Sandvik case study to learn more about the additive manufacturing design process.

Exceeding expectations for cost and design

The resulting design exceeded Sandvik’s expectations and goals for the project. Etteplan was able to design Sandvik’s Geneva drive rotator piece with more than 80% reduction in weight and 5% reduction in price compared to the traditionally manufactured component.

When it comes to metal additive manufacturing , Etteplan Additive Manufacturing & Optimization team has the moto ‘Added value comes from design’. Evidence of this adage was seen clearly in this case.  One of the key factors contributing to the positive outcome was Etteplan’s team approach with deployment of simulation tools and additive manufacturing design expertise. The team succeeded in designing a component which is smaller and largely self-supporting, thus requiring less material, having a shorter build time, and low post-processing costs. With the help of advanced additive manufacturing cost estimation tools, the team was able to estimate the manufacturing costs of the component. This improved the bargaining power of Sandvik in the negotiations with an AM service bureau.

“Etteplan’s expertise in additive manufacturing design is outstanding and we grew our internal knowledge base considerably during the project. With Etteplan’s help we managed to reduce costs and material usage and still get a high-quality component for our product. Etteplan’s additive manufacturing team played also a crucial role in evaluating different printing options and costs and finding the best additive manufacturing printing company for our product”, says Sami Järventausta, Engineering Manager at Sandvik.


Related content

EHTA-Test Factory: Transforming Pulp By-Products into Biofuel

Tampere University is one of the most multidisciplinary universities in Finland. It brings together research and education in technology, health and society. The University is known for its excellence in teaching and research and it collaborates with hundreds of universities and organisations worldwide. Its’ community consists of 21,000 students and over 4,000 staff members from more than 80 countries.

Etteplan helped scaling Q Power's production capacity

Q Power is an innovative Finnish company that specializes in power-to-x deliveries, offering cost-effective and highly efficient technologies for producing synthetic fuels to replace fossil fuels. Q Power’s patented technologies are designed to enable companies to transition towards a fossil-free and self-sufficient energy system, while decreasing their CO2 emissions. With a goal of providing 500 MW of production capacity for renewable synthetic fuels annually by the end of the decade, Q Power is fighting against climate change.

Active Alignment and Bonding of CMOS-to-Lens for Adimec's high-performance cameras

Adimec, a leading provider of reliable and high-performance industrial camera systems, is known for delivering crisp, clear images for the machine vision, global security, and healthcare applications. Achieving high accuracy during the alignment and bonding of CMOS sensors to lens systems is critical for ensuring optimal image quality. To accomplish this, Adimec was supported by Etteplan. By combining active alignment with bonding methods, Adimec creates metrology cameras that offer superior resolution and exceptional performance.

VTT ja Etteplan tasoittavat yhdessä tietä suomalaisille lääketieteen tekniikan alan innovaatioille

VTT on yksi Euroopan johtavista tutkimuslaitoksista. Omistajamme on Suomen valtio. Tehtävämme on edistää tutkimuksen ja teknologian hyödyntämistä ja kaupallistamista elinkeinoelämässä ja yhteiskunnassa. Käännämme tieteen ja teknologian avulla suuria globaaleja haasteita yritysten ja yhteiskunnan kestäväksi kasvuksi. Tuomme yhteen ihmiset, yritykset, tieteen ja teknologian ratkaistaksemme aikamme suurimpia haasteita. Näin luomme kestävää kasvua, työpaikkoja ja hyvinvointia ja tuomme eksponentiaalista toivoa maailmaan.

Developing Autonomous Smart Wood Processing Solutions with ANDRITZ

ANDRITZ is a globally leading supplier of plants, equipment, and services for hydropower stations, the pulp and paper industry, the metalworking and steel industries, and for solid/liquid separation in the municipal and industrial sectors as well as for animal feed and biomass pelleting. Other important business segments include automation and service business. The publicly listed technology Group is headquartered in Graz, Austria, and has a staff of approximately 29,100 employees. ANDRITZ operates more than 280 sites in over 40 countries.

Valmet develops green-transition technology that replaces plastic with new fiber products - Etteplan part of the project team

Valmet is a leading global developer and supplier of process technologies, automation and services for the pulp, paper and energy industries. With Valmet’s automation systems and flow control solutions the company serves an even wider base of process industries. Valmet has over 220 years of industrial history and a strong track record in continuous improvement and renewal.

Contact us
Tero Hämeenaho
Tero Hämeenaho
Department Manager, Additive Manufacturing and Optimization