2023-12-02 08:54:03
After a successful test case with manifolds for a marine engine, MAN Truck & Bus will investigate the possibilities of 3D printing spare parts. The test case was done together with the 3D printing platform Replique and quickly produced ten manifolds that MAN no longer had in stock and for which the casting molds were missing.
It involved ten bronze manifolds for a ship engine from the German engine manufacturer. The manifolds are used for water cooling of the engines.
Traditional process: too long lead time
Making a new mold, casting it and then machining it would not only have entailed high costs but also a long lead time. By 3D printing the parts (with laser powder bed technology), the manifolds were available for repairs to the ship’s engine within seven weeks. All that was needed was a 3D model and a technical drawing.
Better features than original
Replica selected m4p (Brz10) as material, which is technically equivalent to the original material. Production took place using Selective Laser Melting (SLM) via a local 3D printing service from Replique’s network of more than 85 partners worldwide. Tensile tests at MAN’s central materials technology department show that the selected material has better technical properties than the original. The use of these parts in practice was also successful, which is why MAN placed an additional order for 10 pieces.
Digital warehouse
Because the part in question is already qualified for 3D printing and the print file is available digitally, including information regarding the material and technology used, the manifolds can be reordered at any time in consistent quality. MAN incurs no fixed costs for molds and models or storage costs, resulting in attractive total costs per unit for small quantities. MAN now wants to have more parts 3D printed via the Replique network.
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