Exploring Additive Manufacturing for Valve Production Efficiency and Cost Reduction

In modern manufacturing, Additive Manufacturing (AM) offers a game-changing solution for efficiency, design flexibility and cost-effectiveness. Unlike traditional methods, AM allows specific, on-demand fabrication of complex components with up to 99% material usage, thereby reducing lead times and waste.

HP Valves, a global energy industry partner, acknowledges the potential of AM and is collaborating with FIP-AM@UT on the AMII project to evaluate its integration into their production processes. By leveraging AM technology, HP Valves aims to optimise efficiency, align with market demands, and remain competitive in the different sectors they contribute to.

The project’s scope involves a comprehensive examination of HP Valves’ current manufacturing practices and internal knowledge of AM. Through workshops and thorough analysis, the project will produce a quick scan report outlining the current manufacturing setup, key challenges, and an overview of AM processes and methodologies. Additionally, the AMII Valves project will deliver a comprehensive AM implementation plan detailing stakeholder and organizational assessments, potential implementation scenarios, required resources, an implementation framework, and future steps.

The project aims to provide valuable insights into HP Valves’ readiness for AM implementation. By identifying pain points and opportunities within the current manufacturing process, the project will offer a roadmap for leveraging AM technology effectively. With this knowledge and framework in hand, HP Valves will be equipped to navigate the transition towards AM implementation, unlocking new opportunities while mitigating challenges along the way.

Industry partner

APPROACH

The AMII approach follows a five-stage structure to identify and develop the AM potential within the company:

  • Quickscan: gain overview of the company and their products, identify pains and gains in manufacturing, introduction to AM technology and methods
  • Current state analysis: understand company’s structure and alignment of goal for AM implementation
  • Scenario identification: identify and evaluate potential scenarios for AM, knowledge transfer on most suitable methods and materials
  • Scenario development: further definition of scenarios and alignment with AM readiness level and goal
  • Technical implementation plan: synthetise findings and develop a roadmap for AM implementation at the company

OUTCOME

The AMII Valves project has successfully defined a pathway for AM implementation at HP Valves considering manufacturing and organisational aspects.

The collaboration between company staff and researchers in the field of AM, along the AMII process, led to the following key results:

• Assessment of AM readiness levels on skill development, hardware, material, and its integration into the company’s workflow
• Design for additive manufacturing (DfAM) handson experience through fused deposition modelling (FDM) with industry specific designs
• Development of 2 polymer- and 2 metal-based scenarios for implementing AM suggesting most suitable methods and technical considerations
• Technical implementation plan with defined action points for short, mid, and long term, and its integration with the 4 scenarios developed

This project was made possible through the Regio Deal supported by the Province of Overijssel and the Dutch State.

“Partnering with FIP-AM@UT to begin our additive manufacturing journey has proven fruitful and beneficial for our team. The tailored approach has highlighted opportunities for AM implementation across company areas. It has been a smooth transition, supported with the latest in research and experts in the field.””
– Arno Wedzinga
Engineering Manager, HP Valves B.V.

FOR MORE INFORMATION ABOUT AMII Valves, PLEASE FEEL FREE TO REACH OUT TO

Estefanía Morás Jiménez

Research Engineer

Steijn Jonker

Research Engineer