At Wärtsilä, an industrial maintenance task required installing a seal deep inside an engine — a space that was difficult to access. Traditional plastic 3D printed tools weren’t heavy or strong enough for the “slide hammer” technique needed for the job. The engineering team needed a custom 3D printed tool that could withstand heavy use and deliver precision without risk to the equipment.
To meet the challenge, the original plastic/CNC-machined model was quickly redesigned for Laser Powder Bed Fusion (LPBF) production. A fully 3D-printed hinge was integrated into the design, removing the need for any assembly or external fasteners that could loosen and fall into the engine.
The O-ring insertion tool was manufactured at the AM Campus in Finland using metal additive manufacturing and was immediately deployed in Wärtsilä’s factory. This rapid design-to-production cycle showcased the strengths of additive manufacturing in creating safe, durable tools for complex industrial applications.
The new tool eliminated assembly steps, improved handling, and ensured reliability during installation. By leveraging additive manufacturing for industrial tooling, the project reduced downtime and delivered a solution that traditional manufacturing methods could not match.
Through this case, designers at Wärtsilä gained hands-on insights into LPBF design rules, optimal hinge configurations for additive manufacturing, and the technology’s strengths, weaknesses, and surface quality characteristics.
This case shows how rapid tooling with additive manufacturing can deliver strong, safe, and tailored solutions for industrial environments.
Learn more about additive manufacturing possibilities at FAME ecosystem. Join us to collaborate on next-generation manufacturing solutions and accelerate innovation at the AM Campus: contact fame@dimecc.com.
