Additive Manufacturing in Energy Technology: Potentials and Challenges

Additive manufacturing is playing an increasingly important role in the energy sector. The opportunities offered by this technology will be discussed at the Energy Technology & Hydrogen Forum of rapid.tech 3D on May 15, 2025. The focus will be on the use of 3D printing in turbomachinery manufacturing as well as in the production of electrolyzers and fuel cells. Experts from companies such as MAN Energy Solutions, SCANLAB, and Whitecell Eisenhuth will present current developments and challenges.

A key goal of the use of additive manufacturing in energy technology is the reduction of CO₂ emissions.

“We all face the same challenges in the energy sector. Our goal is to apply AM in a way that provides the greatest value for customers. In our case, this primarily means contributing to CO₂ reduction. To achieve this, we need to continue industrializing AM processes—ideally together with all partners in the value chain for the manufacturing and operation of gas turbines. At the forum, we will present both proven applications and discuss further areas for action,” says Ulli Klenk from Siemens Energy.

In the field of turbomachinery manufacturing, MAN Energy Solutions will showcase specific applications where additive manufacturing helps increase efficiency. The focus is not only on the production of complex components but also on the integration of 3D printing into existing industrial processes.

Additive manufacturing is also gaining importance in the hydrogen economy. Burner tips for gas turbines are already being 3D-printed and can now operate largely on hydrogen. Another key area is the production of bipolar plates for fuel cells and electrolyzers. Whitecell Eisenhuth employs additively manufactured structures to reduce production times and enhance component performance. Ralph Mayer from Headmade Materials will present the CMF technology, which combines metal 3D printing with laser sintering, enabling new design possibilities.

Ulli Klenk, a member of this working group, explains: “Across all systems, we observed a high level of comparable quality. The differences lie in cost. What is missing is transparency. We need direct access to process control and machine data to further improve the business case. The technical solutions for this are already available.”

“Here, we are particularly exploring the potential of additive manufacturing for the production of electrolyzers and fuel cells to generate hydrogen with minimal emissions and use it in a ‘green’ way, for example, in the mobility sector,” says Dr. Eric Klemp, who is responsible for this part of the forum.

The specialist forum is part of a comprehensive rapid.tech 3D program, which also covers other industries such as aerospace, chemical engineering, and electronics. In addition to expert presentations and discussion panels, the event will feature practical demonstrations and networking opportunities. The growing importance of additive manufacturing in the energy sector highlights the potential of this technology to make production processes more sustainable and efficient.