ABB Selects Additive Industries’ MetalFAB1 for On-Demand Digital Spare Parts Production

ABB Turbocharging, a manufacturer and maintenance provider of turbochargers, has decided to invest in Additive Industries’ MetalFAB1 platform following an extensive market survey and process evaluation.

ABB plans to use this metal additive manufacturing (AM) system — which is designed for industrial production — to produce spare parts on-demand for its 500 kW to 80-plus MW turbochargers for diesel and gas engines. ABB and Additive Industries are jointly optimizing the integrated process to replace casting and move part fabrication to the digital space.

ABB has over 200,000 turbochargers in its installed base in the marine engine and emergency power generation business. To secure availability for the thousands of different turbocharger spare part designs — which had casting lead times up to nine weeks — a large number of spare parts needed to be carried in inventory. With the MetalFAB1 platform, the spare parts manufacturing lead times can be reduced to a week, so spare parts inventory levels can be reduced significantly.

“In Additive Industries we have found a partner that not only understands what is required to use 3D metal printing in an industrial environment but they also share our passion for digital technologies to continuously improve the service to our customers,” says Egon Seegers, general manager of service part at ABB Switzerland Ltd. Turbocharging.

Additive Industries says ABB is a very focused customer. “They are committed to drive progress in the domain of digital spare part manufacturing, very relevant in a time where shortening the lead times and limiting logistical movements around the world is key,” says Ian Howe, Additive Industries CEO.

ABB services over 200,000 turbochargers around the globe on ships, in power stations, generator sets, diesel locomotives and large, off-highway vehicles. “The potential for on-demand 3D printing of spare parts is immense,” adds Mark Massey, Additive Industries’ CCO. “We are very happy to be able to support ABB in further improving customer service and satisfaction by greatly optimizing the manufacturing process of parts for turbochargers.”