New at rapid.tech 3D:Additive manufacturing in the energy sector, the Energy Technology & Hydrogen Forum makes its debut

Focus on turbomachinery, electrolysers and fuel cells

The first edition of the new forum will focus on two main topics: the use of AM in turbomachinery construction and in electrolyser and fuel cell production. Speakers will include experts from MAN Energy Solutions; ETN Global, the international non-profit membership association for gas turbine technology; SCANLAB; Whitecell Eisenhuth; and Headmade Materials.

“In the energy sector, we all face the same challenges,” says Ulli Klenk from Siemens Energy. “We want to use AM to ensure that our customers get the greatest possible added value. In our case, this primarily means working to reduce CO2. To achieve this, we need to drive forward the industrialisation of AM processes ‒ ideally together with all partners in the gas turbine manufacture and operation value chain. At the forum, we will present tried-and-tested applications as well as discuss the need for further action,” Klenk continues. He and Dr Eric Klemp from Whitecell Eisenhuth, both members of the rapid.tech 3D advisory board, are coordinating the content of the forum.

AM machine data: Transparency required

Anders Such, Head of Additive Manufacturing at MAN Energy Solutions, will present examples of how MAN is using additive manufacturing to produce components more efficiently in turbomachinery and engine construction. He will discuss the potential benefits and challenges that arise from integrating 3D printing into existing industrial production chains.

Action is needed in areas such as standardisation, certification and cooperation between the manufacturers of AM systems and users in gas turbine construction. This topic is addressed by Nicolò Cairo, Project Officer at Energy & Turbomachinery Network (ETN Global); a study conducted by the network on L-PBF (laser powder bed fusion) machines, which are mainly used in the energy sector, also drew this conclusion. The ETN Additive Manufacturing Working Group has evaluated the performance of systems presently available on the market. Group member Ulli Klenk explains: “We found a consistently high level of quality across all systems. The differences are in price. What is missing is transparency. We need direct access to process management and machine data in order to enhance the business case. The technical solutions are there.”

Examples of end-to-end process control

SCANLAB scan systems are among the solutions that enable this openness in terms of data access; they are used by L-PBF machine manufacturers worldwide. Dr Daniel Reitemeyer from SCANLAB’s Business Development department will present examples of end-to-end process control.

Producing and using “green” hydrogen

3D printing is already being used in gas turbine production to manufacture components that are subject to extreme thermal and mechanical stress, such as burner tips. These elements can already use 80 per cent hydrogen instead of natural gas. “We are not far off the 100 per cent mark. But what we need is green hydrogen,” remarks Ulli Klenk, referring to a core problem of the energy transition and leading neatly to the second focus of the forum.

“In particular, we are exploring the potential of additive manufacturing in electrolyser and fuel cell production ‒ the aim being to use these systems to produce hydrogen with as few emissions as possible and use it in a “green” way, for example in the mobility sector,” explains Dr Eric Klemp, who is overseeing this segment of the forum. Whitecell Eisenhuth's Head of Fuel Cell and Additive Manufacturing will also talk about how AM is a useful tool in the production of bipolar plates. These components are essential elements in fuel cells and electrolysers. Whitecell Eisenhuth uses 3D printing processes such as screen printing to speed up the production of bipolar plates; they also perform significantly better and offer a new form of protection against product piracy.

Another 3D printing solution for the production of bipolar plates will be presented by Ralph Mayer, Senior Technical Sales Manager at Headmade Materials, who will introduce CMF (cold metal fusion) technology. This combines the advantages of laser sintering for plastics with metallic 3D printing and is used, for example, in the additive manufacturing of end plates in electrolysers. In particular, the combination of processes and materials offers clear and significant added value.

Specialist conference explores other current AM developments and applications

Alongside the Energy Technology & Hydrogen trade forum, other forums at the rapid.tech 3D specialist conference provide insights into the latest AM developments and applications. On the first day, the VDMA AM4industry Forum, the Aerospace Forum and the quality-approved Science Forum invite visitors to delve into these topics. The Electronics & Components Forum will premiere on day two; also on that day’s programme are the Chemistry & Process Engineering Forum and the Mobility Forum. As well as the Energy Technology & Hydrogen Forum, the final day sees the forums Software, AI & Design and Innovation in AM welcome participants.

Presentations and a chance to chat to exhibitors, Deep Dive tours and Expert Tables

Visitors can also look forward to product and service demonstrations as well as small group discussions in Hall 2 – at the exhibitors’ stands or on guided Technical Deep Dive tours, at the Expert Tables, and at the AM Science Poster Slam in the hall.

The 3D Pioneers Challenge too is a source of inspiration, introducing completely new applications of additive and digital technologies. This year the international competition is back at rapid.tech 3D for the tenth time. The anniversary edition will present the 2025 finalists and see the winners announced. Plus, all previous finalists and winners are encouraged to return for another chance to scoop an award from the jury.