Additive Manufacturing in the Energy Sector: Future Prospects and Applications – Interview with Philipp Pink from Wien Energie

Additive manufacturing is becoming increasingly important in the industry, especially when it comes to the flexible production of spare parts and the optimization of manufacturing processes. The energy sector is also leveraging the potential of this technology to maintain existing infrastructure more efficiently and explore new manufacturing approaches. Wien Energie has been utilizing 3D printing for several years to minimize downtime and produce customized components on-site. Particularly for older power plants, where spare parts are no longer available, additive manufacturing offers a practical solution. In an interview with 3Druck.com, Philipp Pink, Head of 3D Printing at Wien Energie, discusses current applications, the advantages of this technology in the energy sector, and future development plans.

By using additive manufacturing, complex geometries can be realized that would be difficult or impossible to produce with conventional methods. 3D printing is particularly advantageous for small series and custom-made components. Wien Energie combines additive and traditional manufacturing methods to develop optimal solutions for specific requirements.

Within the Wiener Stadtwerke Group, the technology is being further expanded. A joint competence center with Wiener Netze aims to make 3D printing accessible across the entire group. At the same time, certification and quality assurance processes are being established. Wien Energie also continuously analyzes inventory to identify additional opportunities for additive manufacturing applications.

Wien Energie is driving the advancement of additive manufacturing not only through internal applications but also by participating in research projects aimed at exploring new use cases. An ongoing pilot project with a logistics partner is examining how spare parts can be produced on demand and cost-effectively using 3D printing. As an active member of the AM Austria technology platform, Wien Energie is also involved in initiatives to promote and further develop additive manufacturing technologies in the energy sector. By continuously expanding its applications, the company aims to leverage both economic and technical potential in the long term.

Interview with Philipp Pink

In an interview with 3Druck.com, Philipp Pink, Head of 3D Printing at Wien Energie, discusses how additive manufacturing is used to maintain and optimize energy infrastructure, particularly in the production of spare parts and the reduction of downtime. He also talks about ongoing projects, future developments in 3D printing, and the integration of this technology within Wiener Stadtwerke.

What role does additive manufacturing currently play at Wien Energie, and in which areas is it already being successfully applied?

Additive manufacturing has been in use at Wien Energie since 2018 and has proven valuable in various applications. It is primarily utilized for interim solutions and prototype optimization. Wien Energie operates an extensive network of facilities for electricity and heat generation, as well as for other forms of energy production. In older plants, where spare parts and suppliers are often no longer available, 3D printing is particularly beneficial. It allows for the reproduction of obsolete components as well as the development of new parts, significantly facilitating the maintenance and advancement of infrastructure.

What advantages does 3D printing offer for the maintenance and optimization of energy infrastructure compared to conventional manufacturing methods?

The use of 3D printing in the maintenance and optimization of energy systems offers numerous advantages over traditional manufacturing methods. Additive manufacturing enables the realization of complex geometries that would be difficult or impossible to achieve with conventional techniques. Additionally, Wien Energie’s in-house AM production facility allows for cost-effective manufacturing of individual parts or small series. Another key benefit is the fast production time, which helps to reduce downtime and enhance operational reliability. The close collaboration between conventional workshops and the additive manufacturing team ensures an efficient and tailored approach to system operation. This also enables hybrid solutions that combine the strengths of different manufacturing techniques.

How do you see the development of additive manufacturing in the energy sector over the next five to ten years?

Additive manufacturing will play an increasingly important role in the energy sector over the next five to ten years. This trend is not only evident at Wien Energie but also among other companies in the industry, for which we are already developing and manufacturing components. Within the Wiener Stadtwerke Group, this technology is also gaining importance—currently, we are establishing a competence center in collaboration with Wiener Netze to further integrate 3D printing into our operations.

A key focus is on continuously analyzing inventory levels to identify additional applications for 3D printing. At the same time, we are always looking for new technologies and service providers that allow us to expand the range of components we can produce. The potential is significant—both for maintaining our own facilities and for industrial companies that can benefit from innovative manufacturing solutions.

What initiatives and projects is Wien Energie pursuing as a member of AM Austria to advance additive manufacturing in the energy sector and promote its use?

One key initiative is the implementation of additive manufacturing technology within Wiener Stadtwerke (WStW) to make it available across all group companies. This is being carried out in a three-phase approach:

• Phase 1: Development and Communication – Through workshops, roadshows, and targeted knowledge transfer, expertise is being built up, and all group companies are brought to a shared level of understanding.
• Phase 2: Testing and Certification – Relevant components are produced internally and externally tested until certification is obtained for both manufacturing areas and personnel.
• Phase 3: Expansion of Metal 3D Printing – The acquisition of metal 3D printing systems for in-house production, the expansion of the service provider network, and increased communication with workshops and potential customers within WStW are key priorities.

Additionally, there is another pilot project with DB Schenker, where inventory levels are being analyzed to enable cost-effective and on-demand production of components using 3D printing. This project is expected to be expanded to additional Wien Energie sites.

Furthermore, Wien Energie is also actively involved in the projects AM4Rail and its successor AM2Scale to further advance the development of additive manufacturing on a broader scale.

Here you can find more information about Wien Energie.