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. Case Sandvik Expertise Engineering 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. 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.
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.
Etteplan provides CFD for Normet as a part of continuous service in engineering and development Normet is a fast growing and innovative company with a mission to lead the transformation into a more digital and sustainable tomorrow. Within underground mining and tunnelling, they have amassed process expertise in over thousands of projects all over the world. Normet has over 50 years of experience in the industry, over 13000 delivered machines and over 1400 professionals working for the company. Normet’s mission is to lead transformation into digitalized and sustainable underground mining and tunnelling.
