ZEISS Power & Energy Solutions

Additive Manufacturing for Printing and Refurbishing Parts

Additive manufacturing has become a cornerstone in modern production, offering rapid prototyping and enabling the design of new and more complex parts that surpass the capabilities of traditional methods. The technology is increasingly utilized in the production of gas turbine components, such as structural parts, combustion system parts, blades, and vanes. Its relevance extends to the replacement and refurbishment of components during gas turbine maintenance and repair, where parts are rebuilt using welding or reprinting techniques. The widespread adoption of additive manufacturing not only revolutionizes the creation of original parts but also enhances spare part management and opens up new opportunities across multiple sectors.

The challenge

Additive manufacturing starts with the selection of high-quality powder, as the integrity of the raw material is paramount. Any impurities or agglomeration from preceding printing processes can result in the rejection of fabricated parts. The printing process requires accurate path planning to achieve mostly complex geometries and sophisticated part designs, frequently integrating reverse engineering methodologies for the reconstruction of components. The overarching goal is to produce parts that meet the geometric dimensions and are free of defects.
Our solution

Advanced optical measurement systems, including ZEISS ScanBox and ZEISS ATOS 5, provide comprehensive solutions for full-surface measurements. These systems enable the inspection of additive manufactured parts both prior to and following final machining processes. Full-field measurement is essential for the effective reconstruction of parts using ZEISS Reverse engineering tools.

High-precision CMM systems are used to measure relevant machined section.

ZEISS Microscopy Solutions provide high-resolution imaging and analysis, enabling precise examination of material analysis for reprinting or welding. This includes the assessment of powder and raw material quality, as well as the evaluation of printed components.

ZEISS X-Ray Solutions enable the identification of internal defects through non-destructive testing and measurement.

The seamless integration into the workflow allows the processing of batches within the production environment. Comprehensive documentation throughout the product lifecycle, coupled with live feedback for real-time adjustments, using PiWeb reporting.

ZEISS Optical 3D Metrology

ZEISS CMMs