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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.
 

 

 

For more than 150 years, our customers have benefited from KSB innovations in pump and valve technology. However, KSB’s expertise extends far beyond this. With over 20 years of experience in additive manufacturing and rapid casting, we support customers in the production of high-quality individual components. 

Let’s take a look at some exciting projects together.

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. 

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. 

Heat exchanger for a recuperator
Heat exchanger for a recuperator
Heat exchanger for a bearing bracket
Heat exchanger for a bearing bracket
Heat exchanger for a canned motor pump
Heat exchanger for a canned motor pump
Heat exchanger for an oil storage system
Heat exchanger for an oil storage system

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. 

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. . 

Flanged cooling insert
Flanged cooling insert
Impeller
Impeller
Casing
Casing

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. 

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.

Quench reservoir as dry-running protection for a shaft seal
Quench reservoir as dry-running protection for a shaft seal
Leakage sensor for a shaft seal
Leakage sensor for a shaft seal
Special pipe unions, some flow-optimised
Special pipe unions, some flow-optimised

Conclusion

 

With our additive manufacturing and rapid casting service, we provide truly multi-layered solutions for your individual requirements that offer you clear benefits: 

  • Optimised designs with geometric freedom
    Design improvements are possible as parts can be made with fewer components and/or less material/weight. Even complex designs that are difficult or impossible to produce using conventional methods can be created with additive manufacturing methods.
  • Rapid development of innovations
    There is now no need for time-consuming production of expensive prototypes. Instead, product innovations can be designed, tested and implemented in several iteration steps within a shorter period of time. 
  • Save time and costs
    Even small quantities can be individually manufactured quickly and at comparatively low unit costs. Producing “on demand” also eliminates the need for spare parts stockpiling and warehousing.
  • Certified quality
    Over 20 years of experience in additive manufacturing, our accredited test laboratory and certifications from TÜV and DNV give you the certainty of receiving parts of the highest quality. We can provide certification of the material properties of your ordered material at any time.

 

Learn more about KSB SupremeServ Parts On Demand

Quality meets speed – custom-made production redefined

Made-to-order additive manufacturing for all industries

We manufacture your components quickly and precisely to your requirements using innovative additive manufacturing processes and rapid casting. No matter whether you need prototypes, small batches or the reconstruction of components that are no longer available, as a manufacturer with TÜV and DNV certification we produce parts for all makes and a wide range of applications.

Learn more

Do you have any questions or are you already planning a project?

Just contact us. We will be pleased to advise you.

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