Critical AM Parts Ace Field Trials

Critical Additively Manufactured Spare Parts Installed on Vessels as MPA JIP Phase II Comes to a Close

Singapore has been at the forefront of innovation and technology, and 3D printing is no exception. The country's commitment to technological advancement has made it a hub for 3D printing, fitting as home to one of the busiest ports in the world.?

With 3D printing technology, manufacturers can produce complex and customized parts quickly and cost-effectively, reducing the need for costly tooling and equipment. This technology is also transforming the product design process, enabling designers to create intricate and unique designs that were previously impossible with traditional manufacturing methods.

A phase II Joint Innovation Project (JIP) funded by the Maritime & Port Authority of Singapore started in 2021 with an intention to prove the technical capabilities and promote the use of additive manufacturing in the region. This included producing and installing critical components on vessels and tracking performance in use. The core team includes key stakeholders working together in the JIP consisted of Ivaldi Group, DNV, Thyssenkrupp, and Wilhelmsen Ships Service. The project also includes involvement from additional participants such as ship owners, original equipment manufacturers (OEMs) responsible for part design, and additive manufacturers among many other AM eco-system partners.?

"We are excited to be installing critical components onto vessels. A current barrier for entry of AM is the time and cost to certify parts. We know that more success cases will lower the barrier to entry and help to build trust with OEMs and end users, which is why we’re excited to install this valve." - Anna D'Alessio, Director of Engineering of Ivaldi

The JIP members have been working together during the project to resolve questions around technical aspects and cost barriers for certification of critical parts that have so far kept the industry from advancing. Areas that are considered in the project are digitization and part design, optimization, 3D-printing, evaluation of the economic viability of moving components, and certification. The team identified, designed, 3D printed and installed 9 maritime spare parts based on the business case, end user pain points, and the value of the spare itself.?

The parts were a mix of polymer and metal spare parts. We chose both generic and OEM owned parts, partnering with the OEM to gain permission to change designs and approve final parts after performance testing. Based on the criticality parts selected and? produced during the project were certified either by the manufacturer? or a third party i.e., DNV? ? with 3.1 and 3.2? inspection certificate according to EN 10204:2004 to confirm that the testing and inspection process demanded by the specification have been adhered to correctly. ?If required, documentation and test results from manufacturing integrity testing and functional performance obtained during field trials may be submitted to the relevant class society as per standard class procedures, to obtain class certification following the completion of field trials.

"From DNV, we are excited for being part of this Joint Innovation Project (JIP) in Singapore, which aimed to identify and overcome the challenges associated with certifying critical parts, thereby facilitating the integration of additive manufacturing in the maritime sector. Through the successful installation and certification of these crucial components on vessels during field trials, we believe that we have made significant progress in building trust among OEMs and end users. This serves as a testament to the immense potential that additive manufacturing holds for the maritime industry." - Dr. Sastry Kandukuri, Global AM Practice Leader for Additive Manufacturing at DNV Energy Systems.

The 8 parts ranged in criticality and therefore testing requirements for verification. All parts went through a field trial where they were installed and monitored. The results were reduction in manufacturing lead time, improved material performance, solving obsolescence and extending system life, and weight reduction by utilizing design for additive manufacturing techniques. All parts were tested and results were as specified or better.

Additive Manufacturing (AM) technology will play a critical role in achieving a more productive and sustainable maritime industry in the next 10 years. Improving speed, sustainable delivery mechanisms, part performance, and reducing costs are all crucial for the industry's continued success. This JIP, therefore, aims to bring together key industry players along the value chain to showcase the potential of AM technology for maritime and marine parts by printing and certifying critical parts and installing them onboard vessels.?

Contact Ivaldi for access to the report and findings. [email protected]

About Ivaldi

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Ivaldi Group helps heavy industry shift to digital distribution. Working with industry leaders, Ivaldi has helped companies all over the world gain an understanding of their supply chain and build business cases to go digital. Ivaldi will work with you to build a safe, convenient, cost-effective, and environmentally friendly portal for sending files, not parts, whether you are an original equipment manufacturer or end-user.?

About DNV

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DNV is an independent assurance and risk management provider, operating in more than 100 countries. Through its broad experience and deep expertise DNV advances safety and sustainable performance, sets industry standards, and inspires and invents solutions.

Whether assessing a new ship design, qualifying technology for a floating wind farm, analyzing sensor data from a gas pipeline or certifying a food company's supply chain, DNV enables its customers and their stakeholders to manage technological and regulatory complexity with confidence.

Driven by its purpose, to safeguard life, property, and the environment, DNV helps its customers seize opportunities and tackle the risks arising from global transformations. DNV is a trusted voice for many of the world’s most successful and forward-thinking companies.

Contact Info

Email: [email protected] I Website: https://www.ivaldi.com/?