In the mining industry, unplanned equipment downtime can result in significant operational costs. For this reason, fast access to spare parts and shorter manufacturing lead times are important factors in maintaining equipment availability and improving operational efficiency.
3D printing (Additive Manufacturing) is a technology that can, in certain applications, reduce the time required to manufacture industrial components and provide replacement parts more quickly. Swiss company Sulzer has used this technology to manufacture a replacement component for a pump used in a mining application.
The Challenge of Supplying a Slurry Pump Component
In one mining application, a stainless-steel protective component was used as part of a slurry pump. Manufacturing the original component using conventional methods involved processes such as manual cutting and welding, followed by painting.
At the same time, obtaining the original replacement part from the equipment manufacturer could take approximately 6 to 8 weeks. For a mining operation where equipment downtime can be costly, such a long lead time presented a significant challenge.
The objective was therefore to find a faster way to manufacture a replacement component that could match the existing installation.
Sulzer’s Solution: 3D Printing
To address the challenge, Sulzer used 3D printing. The geometry of the existing component was first captured using 3D scanning. The resulting digital model was then used to produce the replacement component.
The new component was manufactured using Acrylonitrile Styrene Acrylate (ASA). This approach enabled the component to be produced without relying on the same conventional manufacturing and painting processes used for the original part.
The replacement component was also designed to match the existing installation so that it could be used within the original assembly.
Benefits of 3D Printing for Pump Components
Depending on the application, 3D printing can offer several advantages in the production of industrial pump components, including:
- Shorter manufacturing lead times for selected components
- Faster production of replacement parts
- Reduced dependence on conventional manufacturing processes
- Reconstruction of existing component geometries through 3D scanning
- Faster prototyping and design modification
- An alternative manufacturing route when original spare parts have long lead times
However, the suitability of a 3D-printed component must always be evaluated according to its operating conditions. Factors such as material properties, mechanical strength, temperature, pressure, abrasion and chemical resistance need to be considered before a printed component is used in an industrial application.
Therefore, 3D printing should not automatically be considered a replacement for conventional manufacturing for every pump component or operating condition.
Reducing Downtime in Mining Operations
For mining equipment, the cost of production downtime can be significantly higher than the cost of an individual spare part. As a result, spare-part availability and manufacturing lead time are important considerations in equipment maintenance.
3D printing can be particularly useful when a component has a clearly defined geometry and needs to be produced quickly. In such cases, the ability to scan an existing component, create a digital model, modify the design and manufacture a replacement can provide additional flexibility.
The value of this technology is therefore not limited to manufacturing speed. The combination of 3D scanning, digital design and 3D printing can also support faster prototyping and alternative approaches to spare-part production.
Conclusion
Sulzer’s use of 3D printing to produce a replacement component for a slurry pump demonstrates how modern manufacturing technologies can help reduce the lead time for selected industrial pump parts.
In industries such as mining, where equipment availability and minimizing downtime are critical, advanced manufacturing technologies can become part of a broader strategy for improving maintenance and spare-part supply.
The appropriate manufacturing method should always be selected based on the component’s design, operating conditions and technical requirements. 3D printing provides the greatest value when it offers a clear advantage in manufacturing time, cost or production flexibility while meeting the required technical specifications.
source: https://t.me/pumpindustryevents
