The perfect solution, layer by layer: Parts On Demand in practice
Whether it's complex designs, difficult material properties or simply the time factor, when a highly specific part is required, finding the right partner is often a time-consuming process. We support customers by providing individual solutions for their challenges via our made-to-order additive manufacturing service.
Discover some of the highlights of our KSB SupremeServ Parts On Demand service.
Whether it's complex designs, difficult material properties or simply the time factor, when a highly specific part is required, finding the right partner is often a time-consuming process. We support customers by providing individual solutions for their challenges via our made-to-order additive manufacturing service.
Discover some of the highlights of our KSB SupremeServ Parts On Demand service.
High-efficiency heat exchangers
Challenge
Heat exchangers transfer thermal energy from one material flow to another.
However, producing these parts is very complicated: the individual components are often manufactured and assembled using different processes. As a result, many heat exchangers can only be made with large dimensions and component weights.
However, producing these parts is very complicated: the individual components are often manufactured and assembled using different processes. As a result, many heat exchangers can only be made with large dimensions and component weights.
Solution
Additive manufacturing processes make it possible to produce components in compact dimensions and without joints, making special geometries such as gyroid structures just as feasible as thin wall thicknesses.
Customer benefits
Our customer benefited from a space-saving lightweight design. We were also able to increase efficiency substantially by optimising the ratio of surface area to volume.
Components for molten salt reactors
Challenge
Particularly in critical applications such as the nuclear industry, high-quality and reliable materials are essential. The molten salt in the reactors requires very high corrosion and temperature resistance above 500 °C.
Conventional manufacturing processes quickly reach their limits when components with complex geometries are needed in this range.
Conventional manufacturing processes quickly reach their limits when components with complex geometries are needed in this range.
Solution
To ensure very high corrosion and temperature resistance, components were additively manufactured in Alloy 625 Grade 2. The 3D CAD data received from the customer was previously checked by KSB's specialist department and prepared for laser powder bed fusion. After successful simulation, we were able to produce pressure-retaining parts, rotating equipment and cooling inserts in accordance with the customer’s requirements.
Customer benefits
Thanks to years of experience and extensive testing processes in our materials laboratory, we were able to provide our customer with proof of the required corrosion and temperature resistance. We were also able to deliver the highly complex component geometries within a very short time. .
Special components
Challenge
Difficult installation conditions are not unusual in special-purpose machines. Special solutions are often required, for example components with complex geometries and/or in high-alloy materials.
However, the small quantities involved result in high costs – and procuring special materials makes the project even more challenging. Special geometries are often the only solution for particularly narrow and problematic installation spaces.
However, the small quantities involved result in high costs – and procuring special materials makes the project even more challenging. Special geometries are often the only solution for particularly narrow and problematic installation spaces.
Solution
Additive manufacturing processes enable parts to be produced as a single piece, i.e. without joints. Reducing the number of production steps also reduces the procurement time.
Customer benefits
Through additive manufacturing we can significantly reduce costs, particularly with high-alloy materials. The reduction in production steps also means a reduction in delivery times for our customers.
On request, our customers receive 3.1 or 3.2 certificates to EN 10204 as proof that the material meets the agreed specifications.
On request, our customers receive 3.1 or 3.2 certificates to EN 10204 as proof that the material meets the agreed specifications.
