Advancing energy innovation with a single-print turbine case

Advancing Energy Innovation with a Single-Print Turbine Case

Case study developed by ROEZ R@D.

ROEZ R@D s.r.o., a Czech research and development company, is driven by a mission to boost energy efficiency and promote sustainable resource use, particularly in nuclear, hydro, and petrochemical sectors.

With a focus on creating specialised prototypes and equipment, the company established its advanced technology centre “Tokáň” and embraced cutting-edge tools, including Meltio's wire-laser metal 3D printing solution, to support its green energy initiatives.

Engineering barriers in energy component production

Developing specialised energy components, like turbine cases for low-potential heat recovery, presents significant design and manufacturing challenges. Conventional methods, such as CNC machining and powder-based 3D printing, proved insufficient due to complexity, cost, and material limitations.

ROEZ R@D needed a solution capable of producing complex internal geometries in a single build without extensive post-processing.

A tailored solution for a high-performance application

The search for a reliable, flexible, and efficient metal AM solution led ROEZ R@D to the Meltio M450. Unlike powder-based printers or robotic welding setups, the Meltio M450 offered an out-of-the-box, standalone system with minimal infrastructure requirements. It supported a wide range of materials, including stainless steel, titanium, and nickel alloys, and enabled autonomous operation with remote control capabilities.

ROEZ R@D used the Meltio M450 to successfully produce a complex turbine case in a single print, using materials like 316LSi and ER70. The system's easy-to-use interface, open material platform, and competitive pricing made it a standout choice. Their goals were to:

• Rapidly prototype and iterate on complex parts without relying on external suppliers.
• Reduce lead times and costs associated with traditional manufacturing or outsourced 3D printing.
• Explore advanced materials previously impractical for their applications.
• Integrate a scalable AM solution into their workflow with minimal disruption.

Key features driving Meltio adoption

• Turnkey metal AM system. The only out-of-the-box wire-laser printer on the market.
• Multi-material capability. A wide variety of alloys (316L, ER70, Ti, Ni-625 and more) from one machine.
• Ease of operation and autonomy. A compact, intuitive interface and reliable remote monitoring, with minimal human oversight.
• Single-print complexity. A one-piece turbine case with internal flow passages in a single build.
• No additional infrastructure. No welding or fabrication station required: true plug-and-play.
• Capital and operating costs. A competitive machine price and wire-only feedstock, compared with highly customised electrodes and setups.

The results

• 85 hours printing time.
• Shortened production cycles.
• Lower operation costs.

At a glance

• System: Meltio M450
• Sector: Energy
• Material: 316LSi Stainless Steel
• Printing time: 85 hours

Building the future of green manufacturing

While challenges remain, ROEZ R@D's experience demonstrates that Meltio's technology can serve as a cornerstone in the transition to a smarter, more sustainable manufacturing. Their journey underscores the potential of wire-laser AM to empower small innovators and reshape the energy sector from the ground up.

This case study was originally published by Meltio as Advancing energy innovation with a single-print turbine case, developed by ROEZ R@D. Reproduced here with credit to Meltio.