The rotating machinery industry is in the midst of a technological revolution. As equipment reliability, efficiency and operational longevity become increasingly critical, manufacturers are turning to advanced manufacturing techniques to push the boundaries of performance. One of the most transformative innovations in turbomachinery engineering today is the adoption of 3D-printed centrifugal compressor impellers.

At the upcoming ROTIC Symposium, where industry leaders converge to discuss advancements in rotating equipment, this breakthrough will be a key topic of interest. 3D printing is not just an alternative to traditional machining—it is reshaping the way we design, produce, and maintain high-performance compressors in power generation, oil & gas and refining applications.

Why 3D Printing is a Game-Changer for Centrifugal Compressors

Historically, manufacturing impellers required extensive precision machining and casting processes, which often resulted in long lead times, high material wastage, and limitations in design complexity. Metal Additive Manufacturing (AM) has eliminated these challenges by enabling the production of intricate, high-strength impellers with reduced turnaround times.

A recent industry milestone saw Rotating Machinery Services (RMS) successfully develop and test large-scale 3D-printed impellers using Inconel 718, a nickel-based superalloy known for its high-temperature strength and corrosion resistance. This technology significantly enhances compressor efficiency by reducing aerodynamic losses and improving overall system stability.

Engineering Challenges and Innovative Solutions

The transition to additive manufacturing in rotating equipment is not without its challenges. Large-scale impellers require meticulous process control, particularly when addressing:

• Melt Pool Instability (MPI): Maintaining material uniformity during the build process.

• Support Structure Optimization: Developing pin-support strategies to minimize distortion.

• High-Speed Spin Testing: Ensuring that printed components withstand operational stresses at up to 115% of nominal operating speeds.

To overcome these hurdles, RMS collaborated with Velo3D and Duncan Machine Products (DMP), pioneering techniques that resulted in precision-balanced, 3D-printed impellers capable of outperforming traditionally manufactured components.