• The global energy demand is rising and a reliable power source is needed
  • A large portion of power added in the next decade will be gas power
  • The increasing demand for electricity will create a subsequent demand for efficient gas turbines
  • Potential for further de-carbonization with gas-to-hydrogen turbines
As cities all over the world are growing fast, their energy demand increases as well

New technologies, new solutions

Dreaming of big and heavy additive parts for the next generation of gas turbines? 

The additive manufacturing process maximizes the design flexibility and allows the integration of additional functions - at no additional costs for extra geometry changes as no prior models or tools are needed. Geometries are no longer limited to the possibilities of traditional technologies.

In addition, with printing space as big as 500 x 500 x 500 mm, we offer serial production of large additive manufactured components with extremely complex shapes integrating more details and functions. 

The GF Casting Solutions 3D-printed demonstrator for industrial gas turbines: 498 x 498 x 425 mm
Material

Alloy X

Density

8.2 g/cm³

Weight

29.7 kg

Volume

3626 cm³

Additive manufacturing with GF

We team up with you

We offer full R&D Service, including material, process and design development; excellent project management and we consult and support during the set-up of specifications.

Printing space

We print in a 500 x 500 x 500 mm printing space. Big and heavy parts are possible as well as small parts in big volumes (part quantity in one print job).

All out of one hand

We offer all post-processes in-house. We have more than 50 years experience in casting and combine it with additive manufacturing in high-end parts. We work time efficiently with one touchpoint in communication.

Finding the best solution

We make objective & reliable technical decisions regarding manufacturing technology (additive manufacturing vs. casting) and experience in customer applications, processes and production costs.

Full speed

Benefit from fast turnaround time, a single point of contact and independence from third parties: All processes from development to finishing take place under one roof.

Proven quality

Our additive manufacturing and follow-up processes are certified according to EN 9100 and Nadcap. Our teams are trained and experienced and take care of the highest standards and quality management.

Our teams are ready to support your 3D metal printing project

Our offer

Our expert teams and certified manufacturing environment are ready to realize your 3D-printing challenge.

In the following, we describe the key players and technologies behind optimized IGT solutions like the 3D-printed GF demonstrator. 

Click on the + to learn more:

Development expertise

Our development team is ready to support you and your project:

  • Support and consulting in the product development process
  • Additive manufacturing oriented and compliant designs
  • Characterization of material properties
  • Static and dynamic validation of components also under thermal boundary conditions
  • Topology optimization and FEM simulation
  • Metallurgical analysis of components 
Our colleagues from the central R&D can set up and optimize your solution - for additive manufacturing as well as for casting processes
Printing space
The printing job in full swing: In the DMP Factory 500 offered by GF Machining Solutions
  • 500 x 500 x 500 mm
  • Big and heavy parts are possible
  • Small parts in big volumes (part quantity in one print job) 
Great design freedom
  • Better design possibilities even compared to casting
  • Extreme shapes: Hollow structures and very thin walls <1mm
  • Very complex shapes from thick to thin in one part
  • Topological optimization: reducing weight and material 
Very complex shapes: hollow and thin-walled structures next to thick areas all in one part
High functional integration
With product development and process expertise, we can integrate multiple functions into one part

Functional integration through product development and process know-how:

  • Integrating up to 40 single parts into one design
  • Reduction of welding for joining and assembly activities
  • Reduction of process steps e.g. tooling and machining processes
Optimized part cooling
The possibilities in 3D printing in combination with the know-how in optimizing of the product design are key to make IGT solutions even better in their functionality.
  • Conformal cooling channels in near net shape design instead of a straight line
  • Complex shapes in additive design instead of additional laser finishing
  • Cost advantage through geometry and performance of the application and the reduction of process steps
Functions such as cooling can be optimized and applied exactly where it is needed
Surface geometry and design
Also the surface design was improved for the optimized cooling
  • Surface enlargement to achieve improved cooling of the component from the outside
  • Flow optimization on the surface with direct impact on air or liquid flow
  • Cost-neutral feature
  • Further application options: assembly surfaces and grip
Bionic design
  • Shaping the product and its structures based on the principles of nature
  • High strength with reduced material and weight
  • Sustainable and cost efficient 

Additive manufacturing process steps

Print job preparation

With state-of-the-art tools and proven expertise, our additive manufacturing team takes care of the print job preparation to make sure that the process can run properly. 

Preparing the printer

We provide the printer with the right powder, clean the optic lenses and take care of the machine calibration.

Print job

The laser is directly melting the component layer by layer. The remaining powder can be reused after a dedicated sieving process.

Depowdering

Once the print job is completed, powder and component are separated automatically and individually. 

Post processes

Our post processing capabilities

  • Vacuum & cryogenic heat treatment
  • NDT inspection 
    (including analog & digital RX, LPI lines, 3D measurement, Zeiss equipment, GOM – Atos measurements syst. and electronic gauges)
  • Welding
  • Airflow test
  • Installation for chemical etching
  • Surface superfinishing processes
  • Finishing and polishing (more than 50 years of experience)
  • HIP**
  • Computer tomography**
  • Machining for semi-finished and finished components**

** not in-house

In our plants in Romania and Switzerland, we offer fully certified post processes for cast and 3D-printed components

Finding the right technology

Additive manufacturing or precision casting? 

The choice for the perfect technology depends on the specific project requirements and needs. GF brings long-standing experience with similar component families from the casting process which is now built upon when offering additive solutions: of course at the same high quality level.

Concept

We keep an eye on cost efficiency, component lifetime, number of parts, geometry and part size.

Precision casting

Depending on your needs and project requirements, the precision casting process may be the right choice.

Additive manufacturing

The flexibility and speed for the manufacturing of complex shapes in AM is unbeatable. With an expert team and certification, we support your 3D-printing project.

Solution

What matters most is the accuracy of your solution and the fit to your needs. GF is your partner for casting and additive manufacturing and helps you decide on the right technology. 

Quality you can rely on

  • Complete additive manufacturing and follow-up processes certified according to EN 9100
  • Trained and experienced teams to handle critical and complex parts requiring highest standards
  • Proven experience in quality management
  • Nadcap standard & certification for all processes

We offer fully certified additive manufacturing, repair welding, heat treatment and non-destructive testing (X-Ray and FPI).

Get in touch with us!

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Your Contact

Marco Salvisberg

Business Development Manager

GF Additive Novazzano SA

Via Gaggiolo 27

6855 Stabio

Switzerland

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