Industrial applications in mechanical engineering

1. Introduction: AM moves into the production hall

For a long time, metal 3D printing in traditional mechanical and plant engineering was considered too expensive, too slow and only suitable for prototypes. This picture has changed fundamentally.

Today, machine builders use additive manufacturing (AM) to overcome design limitations, simplify assemblies and produce spare parts decentrally. This guide highlights the most economical and technically sensible applications in this core industry.

2. Lightweight components for moving masses

In fast-running machines (e.g. packaging machines, textile machines), inertia is the enemy of timing. Every gram that has to be accelerated and braked costs energy and limits the machine speed.

• Robot grippers (end-of-arm tooling): Additively manufactured grippers can be bionically optimized. In addition, compressed air channels for suction cups can be printed directly inside, eliminating the need for external hoses (which often tear off).
• Swivel arms & levers: Printed from Ti6Al4V or aluminum and topology-optimized, they massively reduce the mass inertia and increase the service life of the drive motors.

3. Flow-optimized components (fluidics)

Classically milled distribution blocks consist of solid metal blocks into which holes must be drilled from the outside and then closed with plugs. This leads to 90° flow deflections, pressure losses and dead water spaces.

• Hydraulic and pneumatic blocks: Curved, flow-optimized channels can be constructed using 3D printing. The result: The component is up to 80% lighter, more compact, has less pressure loss and no potentially leaky plugs.
• Nozzles & Mixers: Special nozzles in which different fluids have to be mixed precisely can often only be produced additively.

4. Spare parts supply “on-demand”

In plant engineering, spare parts often have to be kept for machines that are 30 years old. The physical storage of castings or machining raw parts causes massive storage costs (capital tied up).

• Digital inventory: CAD data replaces the physical warehouse. If a replacement part is needed, it will be printed locally.
• Obsolete parts (reverse engineering): If there are no longer any blueprints for a defective part, it is 3D scanned, modeled in CAD and printed within a few days (often using DED or PBF).

5. Tool making for mechanical engineering (devices)

In addition to the components for the end products, machine builders constantly need internal resources.

• Assembly devices: Complex gauges and holders can be printed precisely to suit the ergonomics of the employee and the geometry of the workpiece.
• Induction coils: Copper coils for induction hardening (e.g. of gears) can be printed directly with pure copper (via green laser PBF). They have a significantly longer service life and better cooling than bent and soldered copper pipes.

6. Integration of WAAM in large mechanical engineering

While PBF is ideal for small valves and grippers, WAAM (Wire Arc Additive Manufacturing) is conquering large machine and plant construction.

• Instead of waiting weeks for large forgings or castings (e.g. large flanges, turbine housings), WAAM builds the near-net-shape blanks within a few days. Then only the critical functional surfaces are milled.
• This saves lead time, reduces dependence on global supply chains and drastically reduces material waste.

7. Conclusion: A paradigm shift in engineering

Mechanical engineering is historically shaped by the limitations of milling and lathe machines. “You can’t mill it like that” is the mantra of many designers. The successful use of AM in mechanical engineering therefore primarily requires training of engineers in **Design for Additive Manufacturing (DfAM)**.

Once these mental shackles are broken, metal 3D printing becomes one of the most powerful tools for innovation in mechanical and plant engineering.