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1.1.1 Industrial Application of Metal AM in the Energy Sector

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Industrial applications of functional metal AM components can be found across various sectors including nuclear power, oil & gas, turbine components, wind & tidal energy, fuel cell components, and electromagnetic energy to name a few. Some such applications are discussed in this subsection. The GE Leap fuel nozzle was one of the first certified metal AM components to undergo high‐critical testing and deployment into production [7]. Siemens has been at the forefront of metal AM applications with replacement parts for nuclear plants, sealing rings for steam turbine blades and high‐efficiency gas turbine burners [8]. Oerlikon has showcased topology optimized turbine blades and drill bits for oil & gas applications with integrated sensors [9]. Biome renewables has designed and retrofitted an AM part to increase efficiency of existing wind and tidal turbine installations [10]. Aidro has manufactured high‐pressure hydraulic manifolds and heat exchangers for oil & gas applications [11]. The Oakridge National Lab (ORNL) has demonstrated a newly designed nuclear reactor core with multi‐material and integrated sensor functionality planned in the near future [12]. Optisys manufactures high‐performance antennas for critical electromagnetic energy sensor applications for satellites [13]. Thermal management applications—like heat exchangers, fuel cell components, and rocket nozzles—greatly benefit from the design freedom offered by metal AM [14]. The diversity of potential applications for metal AM in the energy sector is just starting to be explored. A better understanding of the potential can be gained by reviewing recent advances in functional metal AM components by classifying the functionality according to geometric and material gradients.

3D Printing for Energy Applications

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