Metal 3D printing in shipbuilding
We are pleased to announce that our company is now a member of the Network for 3D Printing in the Maritime Industry (MN3D). The group’s common goal is to optimise additive manufacturing methods and bring products specifically for the maritime sector to market.
The MN3D network comprises 29 partners and we are looking forward to a lively exchange on the possibilities of additive repair, 3D generation and laser cladding for various maritime applications. We see great potential for this industry, especially in our ProFocus product line, in order to meet the special requirements resulting from the size of the components and their exposure to low-frequency vibrations and seawater.
Users in the shipbuilding industry can already benefit from new technological and economic advantages, such as the 3D repair of high-value components. This saves a company considerable costs compared to buying new components, not to mention potential supply chain problems.
Knowledge of the possibility of coating components with high-performance wear protection materials, e.g. nickel and cobalt-based alloys, is also becoming increasingly widespread, extending the service life of stressed components in the long term. With a focus on cost-effectiveness, quality and customer needs, OSCAR-PLT is well placed to provide future-proof solutions for the maritime industry.
Contact our experts now to find out more about new possibilities for metal 3D printing and additive manufacturing in your industry.
Metal 3D printing in shipbuilding
The ProFocus system from OSCAR-PLT and the STELLOY 21-LD cobalt-based welding wire from Welding Alloys – the perfect complement for laser wire hardfacing.
Both are known for their excellent suitability for high-performance applications and are therefore particularly suitable for demanding industrial applications such as the hardfacing of hot shear blades used in forging.
Video highlights:
Material properties: ProFocus metal 3D printing/wire laser metal deposition (w-LMD) provides a clean surface finish and works well in complex welding positions.
Laser hardfacing: The video describes laser hardfacing, which uses a laser to deposit wire onto surfaces that require higher hardness and durability. This method allows for precise and controlled deposition, resulting in a high-quality, uniform hardfacing layer.
Industrial applications: Industrial hardfacing with metal 3D printing/w-LMD improves the durability and performance of hot shear blades in the forging industry. The improved wear resistance of the armoured blades leads to a longer service life and lower maintenance costs.
This video highlights the benefits of using metal 3D printing/w-LMD for laser armouring and emphasises its superior performance in harsh industrial environments.
Would you like to find out more about the future of industrial hardfacing? Don’t hesitate to get in touch, we look forward to talking to you!
The future of industrial hardfacing
With the ProFocus technology from OSCAR-PLT, companies are already saving several 100,000 euros per year. ProFocus opens up new economic and technological possibilities, even with complex geometries and difficult materials.
Conquer new frontiers with ProFocus
Until now, additive repairs on materials such as tool steels or cast iron were often not possible or only possible to a limited extent, as the melting zone of classic welding processes is too large. ProFocus solves this problem and offers an optimum range of applications, without preheating and even for components that could not previously be repaired.
Proven technology
Reliable, with numerous first-time-right applications
Safe & flexible
Easy switch between wire and powder in a few seconds
Absolute control
ntegrated HDR process monitoring and automatic height correction
We’re with you every step of the way
Since 2013, OSCAR-PLT has helped dozens of companies to develop successful new business models and introduce pioneering technologies. We see our customers as long-term partners and assist them with comprehensive consulting, pre-testing, training and agile technical support.
Sounds interesting? Contact one of our experts now, we look forward to talking to you.
3D repair or new purchase – take the right choice
Industry faces major challenges when it comes to the maintenance of large components. As this case study shows, additive repair creates attractive economic opportunities: Mining companies are already saving several 100,000 Euros per year.
OSCAR-PLT’s ProFocus laser technology has been on the market since 2019. Since then, it has proven its reliability in industrial use, time and again. A complete turnkey system from OSCAR-PLT, the ProFocus Laser Cell, has also been available since the end of 2023 – another pioneering tool for additive repair.
Case study: repair welding in open-cast mining
A current example of the capabilities of the ProFocus system is the repair of bearing shells in the bucket wheel gearbox of open-cast mining excavators. The components, which weigh several tonnes and measure 4 x 2.5 x 4 m³, are welded directly onto the worn area thanks to the flexible robot-guided positioning of the laser head.
In the past, the time required per repair was up to 180 hours, as housing bores had to be laboriously joined with bushes and spindled out. With ProFocus, the turnaround time is now only around 40 hours.
Michael Schnick, Managing Director of Oscar PLT, comments: ‘Our aim is to work with our customers to redefine the limits of what is possible in additive repair.’
Results at a glance
- Cost savings of hundreds of thousands of euros per year by minimising downtimes as well as new part and storage costs
- Minimised downtimes: repair times of 40 instead of 180 hours, with the same, and in some cases even improved, quality.
- Decarbonisation: opting for additive repair means considerable CO2 savings.
- Greater flexibility: Complex geometries can also be repaired on the move and in hard-to-reach places.
Additive repair with ProFocus offers clear advantages for maintenance, and not just in open-cast mining. Large components can also be repaired efficiently, cost-effectively and reliably in other branches of industry. In addition, the service life of machine components is extended thanks to new material combinations and the associated mechanical and tribological improvements.
Automated control
A key element of the ProFocus line is its user-friendly operating system. HDR cameras provide detailed images of the welding process and enable seamless process control and regulation. Automatic correction of the working distance ensures maximum precision.
Sensors guarantee permanent contact between wire and component, and prevent the melt from breaking off. Infrared cameras recognise local hotspots and control the optimum application of heat to the component to be repaired.
OSCAR-PLT’s ProFocus technology not only provides solutions for current challenges in additive manufacturing, but also a vision for future business models. With comprehensive advice, preliminary tests, training and agile technical support, OSCAR-PLT stands by its customers as a long-term partner.