Power and renewables

DNV to industrialize new quality platform for industrial 3D-printing solutions

A 3D-printed burner-front with about 8700 layers of high-temperature Nickel-superalloy. The printing process takes about a week and is performed in a L-PBF machine with a quadruple laser system designed for serial manufacturing. The advanced geometrical shapes possible with 3D-printing are particularly valuable for improved mixing of fuels and air, as well as for better cooling of the flame-exposed surfaces.

DNV and Siemens Energy's global additive manufacturing business unit are joining forces to create a quality assurance platform for the 3D-printing industry. The collaboration will accelerate commercial AM production with quality control at every stage and layer in the printing process.

DNV and Siemens Energy are about to take additive manufacturing (AM) – also known as 3D-printing – into the next stage of maturity. Siemens Energy's experts in Finspång, Sweden, have developed the first generation of the AM Cockpit platform providing automated, reliable quality control of the 3D metal printing process. In turn, DNV has developed the Independent Quality Monitor (IQM) platform – a customer portal that continuously quality-assures digital solutions.   

By combining these two solutions, DNV can launch a commercial solution for the AM manufacturing industry – ensuring that 3D-printed parts can easily be compared to a so-called approved master print. The combination also makes automated and remote process certification possible. 

Successful combination of two platforms

The AM Cockpit collects sensor data streams and powder bed images from the manufacturing process in powder bed fusion 3D-printers. The AM Cockpit then generates a digital summary of each printed part, highlighting problematic areas of the print.   

In parallel, the IQM has been developed as part of the EU-project InterQ, aiming at zero-defect manufacturing. The solution monitors data quality continuously through newly developed algorithms and compliance logic.

Klas Bendrik, Chief digital and development officer at DNV
Klas Bendrik, Chief digital and development officer at DNV

"Succeeding in AM industrialization relies on a successful digital transition. The combination of the AM Cockpit and the IQM is a significant step forward for additive manufacturing," says Klas Bendrik, Chief digital and development officer at DNV.   

By industrializing the combined solution, DNV aims to become the global energy sector's preferred choice for digital risk management.   

Senior engineer and AM specialist Stian Gurrik has been central in working with DNV's recommended practices on additive manufacturing. He sees several benefits of the collaboration between DNV and Siemens Energy.  

"The benefits of 3D-printing, when used properly, can include reduced material waste, quicker production, cost savings and the ability to produce complex and customized parts," Gurrik says. 

Enabling industry decarbonization

Siemens Energy is leading the way in the energy transition – covering the entire spectrum of energy solutions and supporting its customers' ambitious decarbonization targets.  

As a pioneer in AM, Siemens Energy has been a global front-runner in designing and 3D-printing key gas turbine components that enable power plant owners to increase their plant's efficiency and significantly reduce carbon emissions today.   

"Thanks to its design freedom, AM is the core technology that allows Siemens Energy to develop and modify gas turbines to run on green fuels, such as hydrogen," says Hans Holmström, CEO of Siemens Energy in Sweden.   

"With decades of experience in industrializing additive manufacturing, Siemens Energy is an excellent partner for DNV in advancing quality assurance of additively manufactured parts," says Manish Kumar, Head of business development, strategy and sales of Siemens Energy Additive Manufacturing Business

The quality of a printing process can be visualized with the digitalized quality assurance method of the AM Cockpit and the IQM. As a result, the end user can be confident that the process meets the necessary quality standards.

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About DNV

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.

In the energy industry

DNV provides assurance to the entire energy value chain through its advisory, monitoring, verification, and certification services. As the world's leading resource of independent energy experts and technical advisors, the assurance provider helps industries and governments to navigate the many complex, interrelated transitions taking place globally and regionally, in the energy industry. DNV is committed to realizing the goals of the Paris Agreement, and supports customers to transition faster to a deeply decarbonized energy system.

About Siemens Energy 

Siemens Energy is one of the world's leading energy technology companies. The company works with its customers and partners on energy systems for the future, thus supporting the transition to a more sustainable world. With its portfolio of products, solutions and services, Siemens Energy covers almost the entire energy value chain – from power generation and transmission to storage. The portfolio includes conventional and renewable energy technology, such as gas and steam turbines, hybrid power plants operated with hydrogen, and power generators and transformers. A majority stake in the wind power subsidiary Siemens Gamesa Renewable Energy (SGRE) makes Siemens Energy a global market leader for renewable energies. An estimated one-sixth of the electricity generated worldwide is based on technologies from Siemens Energy. Siemens Energy employs around 92,000 people worldwide in more than 90 countries and generated revenue of €29 billion in fiscal year 2022.

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