The energy industry continues to grow, and additive manufacturing for the energy sector, also known as 3D printing, is becoming a popular solution to many of the industry's challenges. But how can this technology help design more sustainable processes for energy production and storage?
Additive manufacturing: a powerful lever for the energy transition
How 3D printing meets the challenges of the energy transition
3D printing for energy
The parts we focus on are both the components used to produce energy conversion devices (systems designed to transform energy from one form to another) and those that enable the maintenance, repair, or improvement of existing production systems. These types of equipment include energy generation technologies such as wind turbines or solar panels, as well as conversion equipment such as batteries and generators. A multitude of other equipment can be created through 3D printing for energy, such as reduced-scale models and prototypes used to improve and transform products into their final complete form!
Therefore, we see that additive manufacturing is capable of applying to many projects and in various application cases, but what are the notable advantages and benefits that make it an emerging technology ?
What are the advantages of using additive manufacturing in the energy sector ?
The components used to produce energy conversion devices, such as wind turbines, solar panels, batteries, and generators, can all benefit from the advantages provided by the 3D printing and at different scales. Additive manufacturing can be applied, for example, for:
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Rapid prototyping
Using 3D printing, you can build prototypes quickly and conduct more reliable tests, which can speed up the product development process. In just a few days, you can obtain a functional prototype and proceed with iterations based on simulation results. This faster prototyping method can reduce costs and development time while speeding up the time to market. -
Improved performance and material savings
For example, solar panels can be produced with increased precision using this technology, reducing costs associated with the loss of expensive materials. According to the Massachusetts Institute of Technology (MIT), these savings can contribute to a 50% reduction in solar panel manufacturing costs. Additionally, the precision offered by 3D printing can increase solar panel efficiency by 20% during solar energy exploitation, according to MIT. -
Specific part repair
Using 3D printing for maintenance of energy production and transformation infrastructure and equipment can significantly reduce downtime and energy production disruptions. This technology allows for on-site repair of complex parts in just a few hours or days, whereas previously it could take several weeks and immobilize production. This approach ensures increased profitability and reduced losses, as shorter downtime leads to more efficient production. -
Flexibility with reverse engineering
Equipment manufacturers, when they stop producing obsolete parts, make mechanical troubleshooting for energy producers difficult. Without the ability to restock on parts and without access to the original CAD files, it is often necessary to replace the entire equipment. However, 3D printing can overcome these challenges by implementing a reverse engineering process with Siemens NX to produce or repair necessary replacement parts. This new production and/or repair approach based on an existing physical model allows you to produce parts on demand rather than overloading your inventory with spare parts for fear that the supplier may stop producing them. -
Customization according to needs
Traditional manufacturing processes often have design constraints that can be due to molds or the machining capabilities of the manufacturer, for example, but 3D printing offers much greater design freedom. This technology makes it possible to adapt the design to the specific needs of each energy project, facilitating the creation of complex and customized energy production systems.
Innovative projects in the energy industry have been made possible thanks to additive manufacturing
Creating solar cells with 3D printing
Conventional solar cells have various problems such as the need for high-temperature production, environmental impacts, and high costs despite their fragility. However, a project called T3DP has developed a 3D printing method for producing solar cells that outperform standard flat panels. This technology uses Perovskite, an inexpensive semiconductor material that allows for the production of low-temperature solar cells. Volumetric 3D printing is used to create solid and stable hexagonal knits with the solar material.
IBM has developed 3D-printed batteries
In partnership with the Swiss Federal Institute of Technology in Zurich, IBM has successfully 3D-printed the first liquid battery capable of cooling and generating energy simultaneously. To achieve this, electrolytes were used to create mini-channels that feed the device. This technology holds promising potential as it reduces the risks of overheating and the power requirements of the battery.
3D-printed wind turbine blades that are fully recyclable
Researchers from the National Renewable Energy Laboratory (NREL) have developed an additive manufacturing process that allows for the production of easily recyclable wind turbine blades. But there is even more innovation on the horizon ! While traditional wind turbine blades become obsolete after 20 years and the fiber and resin cannot be separated, the association From Waste to Wind is developing a 3D printed wind turbine model using rPET, which is recycled and recyclable plastic used for bottled water. This shows that additive manufacturing is enabling advancements in the energy production industry.
Additive manufacturing: innovative opportunities for the energy sector
3D printing offers great potential for the energy sector, by reducing production costs, improving energy efficiency, and allowing for increased customization of parts. The future of additive manufacturing in the energy sector is very promising. 3D printing technology has already demonstrated its potential in the production of customized parts for wind turbines, as we have seen earlier, gas turbines, and solar energy production equipment.
Today, manufacturers can use 3D printing to produce complex parts with high precision that are difficult or impossible to achieve with traditional manufacturing methods. Siemens NX design software already supports this type of project. The Siemens NX design software already supports this type of project.
Moreover, 3D printing can also contribute to the transition to more sustainable energy sources, by enabling less costly and more efficient manufacturing of parts for technologies such as wind turbines and solar panels. In summary, additive manufacturing has the potential to revolutionize the energy sector by enabling cost savings and performance improvements.
As the technology continues to develop, we can expect to see more and more applications in renewable energy production and in the optimization of traditional energy production. Manufacturers must stay abreast of the latest technological advances and consider incorporating 3D printing into their manufacturing processes to remain competitive in this ever-evolving market.
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