Challenge:
SABIC faced significant challenges with the production and maintenance of fan blades used in cooling electrical motors. Traditional manufacturing methods resulted in long lead times, high costs, and frequent downtimes due to the need for replacements. The existing fan blades had to be replaced frequently, leading to increased downtime and maintenance costs.
Solution:
Fan Blade
- Design for Additive Manufacturing (DFAM): The original fan blade design was optimized for 3D printing to ensure high precision and performance. Design modifications were made to enhance durability and efficiency.
- Material Selection: PA 12 was chosen for its excellent mechanical properties, including high tensile strength and resistance to wear and tear, making it ideal for the operational environment of electrical motors.
- 3D Printing Technology: The fan blades were produced using Selective Laser Sintering (SLS) technology. This method enabled rapid production, high accuracy, and the ability to produce complex geometries that traditional manufacturing could not achieve.
- Increased Efficiency & Reliability: The new fan blades significantly improved operational reliability, reducing the frequency of replacements and downtime. This improvement directly contributed to better cooling performance and extended motor life.
- Cost Efficiency: Overall costs were reduced by eliminating the need for extensive logistics and large inventory holdings. The reduction in downtime and maintenance also contributed to significant cost savings.