Lightweight Precision: How 3D Printing Transformed Cable Inspection

Suprotech

The client

Suprotech specializes in the inspection, maintenance, and repair of high-stakes infrastructure components, particularly focusing on stay cables used in large-scale structures like flare stacks. Utilizing advanced technologies such as 3D scanning and magnetic inspections, Suprotech ensures the structural integrity and safety of these critical components. Their innovative approach, including the development of specialized trolleys for cable inspection, has positioned them as a leader in the global market for industrial maintenance solutions. Suprotech's commitment to safety and efficiency drives their continuous innovation in this highly specialized field.

The challenge

The main challenge for Suprotech regarding the crawler (trolley) was its excessive weight, which led to significant friction on the cables during inspections and maintenance. This friction not only made the crawler less efficient but also posed potential risks to the cables themselves. Additionally, the original design included heavy, conventionally manufactured components and rubber sleeves that created resistance, further complicating the inspection process. Suprotech needed a solution that would reduce the crawler’s weight while maintaining or improving its functionality, ultimately leading them to explore custom-made, 3D-printed parts as a potential solution.

Additive Center was chosen as the ideal partner due to our expertise in 3D scanning and printing technologies. Our ability to design and produce lighter, tailor-made components, while maintaining the necessary strength and durability, made us the perfect choice to address Suprotech's specific needs and drive the project forward.

The solution to Suprotech’s challenge was to redesign the heavy components of the crawler using advanced 3D scanning and printing technologies provided by Additive Center. By scanning the cables and creating custom, lightweight 3D-printed parts, Additive Center was able to reduce the crawler’s weight significantly while enhancing its functionality. The new design included split plastic sleeves that fit precisely around the cable strands, reducing friction and improving overall efficiency. This innovative approach not only solved the weight issue but also improved the crawler’s performance and expanded its usability.

The result

The advantages

Reduced Weight

The redesigned, 3D-printed components significantly decreased the crawler’s weight, reducing friction on the cables and making the inspection process smoother and more efficient.

Enhanced Performance

The custom-fit plastic sleeves ensured optimal sealing and reduced resistance, improving the crawler’s overall functionality and allowing for more precise and effective inspections.

Broader Usability

The lighter, more efficient crawler can now be used in a wider range of applications, making it a versatile tool for various inspection and maintenance tasks, thus expanding its operational scope.

Increased Durability

The materials and design used in the 3D printing process were chosen for their strength and longevity, ensuring that the new components could withstand the rigors of regular use while maintaining performance.

Additive Center takes great pride in being a founding member of AMcubator. This ecosystem enables us to collaborate with other top-tier companies to achieve optimal results. What distinguishes AMcubator is our steadfast dedication to delivering tangible business value. From housing leading 3D printing companies to providing cutting-edge equipment in our pilot factory, AMcubator offers a distinctive platform for collaboration and innovation. Our objective? To streamline your AM journey, enhance processes, and ultimately propel scalable applications to market success. Interested in discovering how AMcubator can add value? Click here to learn more.

The following companies contributed to this specific project:

Hexagon played a key role in this project by conducting finite element analysis (FEA) on the 3D-printed components of the crawler. Their advanced simulation tools evaluated the mechanical properties and structural integrity under operational loads and stresses. By running these simulations, Hexagon ensured that the redesigned parts would be both lightweight and capable of withstanding the high tensile and compressive forces encountered during inspections. This technical validation process minimized the risk of structural failure and guaranteed that the crawler would maintain optimal performance and durability in demanding environments.