Harboursandport.com: Singapore - DNV, the independent energy expert and assurance provider has awarded Keppel Technology & Innovation (KTI) a verification certificate for the world’s largest 3D printed deck mounted type Panama Chock (SWL150Ton).
The component, which is intended for non-class maritime
applications are the world’s largest 3D-printed shipboard fitting.
Panama Chocks are large shipboard fittings for towing and
mooring, traditionally manufactured by casting, and are welded to a ship as a
supporting hull structure. This component was manufactured by KTI’s partner
AML3D (ASX: AL3) using their patented Wire Additive Manufacturing (WAM®) process
which used medium strength structural steel grade ER70S-6 wire feedstock.
A statement signed by Head of Media Relations, Energy
Systems, Neil Slater noted that “the verification by DNV follows extensive
research, production, and testing by KTI with end-users Keppel Offshore &
Marine (Keppel O&M) and technology partners AML3D and confirm that the
component has met all the primary test requirements in KTI’s project material
specification with satisfactory results.”
Slater further explained that Francois van Raemdonck,
Managing Director of KTI said “KTI
has been working on this project with Keppel O&M, DNV, and AML3D since 2019,
and we are proud to achieve this endorsement. Keppel is transforming the way it
harnesses technology and KTI is supporting this by collaborating with Keppel
business units to innovate and create value. This is in line with Keppel’s
Vision 2030, which includes leveraging advanced technologies to drive growth.”
He pointed out that “additive manufacturing (AM) – the
industrial equivalent of 3D printing – is an emerging technology which uses 3D
model data to fabricate parts, enabling, among other benefits, significant time
savings. Wire Arc Additive Manufacturing, or WAAM, has the potential to enable
a productivity step change in shipbuilding, and is able to 3D print marine
grade metal structures at a scale well beyond other commercially available
metal 3D printing technologies.”
Similarly, he
noted that Aziz Merchant, Executive Director of Keppel Marine & Deepwater
Technology, the technology arm of Keppel O&M, said “Keppel O&M is constantly exploring new technologies
to stay ahead in the industry and additive manufacturing has the potential to
increase the efficiency of shipyard operations. The 3D printing of Panama
Chock shows that large components can be made available with shorter lead times
and with equal standards of quality and performance. We are encouraged by the
verification and we look forward to exploring how AM can be implemented on a
wider scale.”
He noted that “as part of the
qualification process a 1,450 kg Panama Chock was designed and produced to meet
international standards and KTI’s project-specific material specification.
Material yield strength was twice that of the original cast material and was
produced with acceptable internal soundness that was confirmed by various
non-destructive testing and evaluation methods.
“The part was then proof load tested to 20 per cent higher
load than its design working load. Following the successful load test,
non-destructive and destructive testing, and the results were reviewed by all
parties before the final verification statement was issued.
“It’s pleasing to see further
advances within the offshore and marine industry with this development for the
world’s largest 3D printed shipboard fitting. Creating trust is critical for
the acceptance of 3D printed parts and DNV’s certificate plays an important
role in ensuring that this is the case” said Brice Le Gallo, Regional Director, Asia
Pacific Energy Systems at DNV.
Dr. Sastry Kandukuri, Senior Principal Materials
Specialist, Energy Systems at DNV, added: “I am
very happy our Global Additive Manufacturing Technology Centre of Excellence
was able to support KTI to reach this milestone. Our team of multidisciplinary
experts across DNV with a combined AM service experience of 20,000+ hours look
forward to continuing to work together with KTI as they develop and qualify
AML3D’s WAM® 3D printing capabilities.”
Also, AML3D Chief Executive Officer, Andrew Sales
said, “We’re proud to have
been able to partner with KTI and demonstrate the advantages of our patented
Wire Additive Manufacturing (WAM®) capabilities in the creation of the world’s
largest 3D printed Panama Chock. Additionally, we are equally as excited to see
this WAM® printed component receive official verification by DNV. This now
offers a quality assurance pathway for a wide range of components that can
follow a similar validation process. It is a fantastic achievement by DNV, KTI,
the AML3D team, and our other partners in this project. Working with KTI’s
vision for implementing AM has been a further endorsement for our own business
model and we’re excited about the future,” he noted.
The Head of Media Relations, Energy
Systems, also said that “The printed material (Panama Chock) was subjected to
extensive testing by the DNV Singapore Laboratory and the Marinelift Testing
& Supply Pte Ltd. Singapore. Researchers and testing engineers utilized
advanced microanalysis instrumentation to generate high-quality microstructural
information and images. In addition, the mechanical and non-destructive testing
were assessed and compared against established marine-grade cast material.
“Throughout the production and
testing processes, there was close and collaborative engagement between DNV,
KTI and AML3D. Factors such as functional specifications, safety, testing
procedures and acceptance criteria were all subjected to scrutiny by experts,”
he noted.
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