The National Renewable Energy Laboratory (NREL) has installed a new laser-powered metal 3D printer at its Flatirons Campus to support marine energy device development. The printer, customized by Tennessee-based One-Off Robotics with U.S. Department of Energy funding, can produce metal components up to 1 meter long for testing wave, current, and tidal energy systems.
Marine energy devices require metal components that can withstand harsh ocean conditions. “Compared to plastic, metal components can withstand five to 10 times as much force,” said Paul Murdy, a mechanical engineer at NREL. The printer operates with lasers reaching temperatures of at least 2,500 degrees Fahrenheit to melt and deposit stainless steel in precise layers.
The eight-axis printer offers advantages over NREL’s existing desktop-sized 3D printers by enabling full-scale prototype testing. “We have a good amount of experience doing rapid prototyping and additive manufacturing with smaller machines,” said NREL research engineer Casey Nichols. “But getting a larger 3D printer lets us do more at-scale research.”
Beyond marine energy applications, the printer can produce components for water heaters, shipping vessels, and aerospace technologies. NREL researcher Charles Candon noted that teams previously waited up to nine months for metal parts but can now produce them within days. The technology addresses supply chain delays while supporting rapid prototyping needs across multiple industries.
The marine energy sector has potential to provide up to 60% of U.S. electricity needs, though capturing all available energy remains impractical. NREL researchers plan to use the printer to test different device designs and manufacturing methods that could reduce costs and improve the commercial viability of marine energy technologies.
Source: nrel.gov