3D printing for a more resilient power grid

About the project

A robust power system depends on critical components and spare parts being available when they are needed. In the event of major disruptions, interruptions to international supply chains or, in the worst case, war, access to spare parts can become a decisive factor in how quickly the electricity supply can be restored.

In this project, RISE is investigating how additive manufacturing, often referred to as 3D printing, can be used to strengthen preparedness in the power grid sector. By enabling local and flexible production of spare parts, dependence on global supply chains can be reduced while lead times for critical components can be shortened.

The project focuses on spare parts for high-voltage equipment in the power grid, covering voltage levels between 10 and 130 kV.

Background

Experience from international crises and attacks on energy infrastructure shows that restoration efforts are often limited by access to equipment and spare parts. At the same time, additive manufacturing is developing rapidly and is already used in several industrial sectors to manufacture or repair components at short notice.

Despite this, there is currently a lack of knowledge about which spare parts in the power grid sector are suitable for 3D printing, what requirements need to be met and how such production could be organised in practice during a crisis.

Objectives

The overall objective of the project is to identify opportunities to manufacture critical spare parts for high-voltage equipment in Sweden using 3D printing.

The work will include:

• identifying the spare parts most relevant for production using additive manufacturing 
• mapping technical requirements, standards and limitations 
• assessing which properties may be acceptable for temporary emergency components in a crisis 
• describing workflows for digitalisation, manufacturing, post-processing and validation 
• providing a basis for future full-scale testing and demonstration projects 

Implementation

The project combines expertise in power systems, high-voltage technology and additive manufacturing.

The work includes:

• analysing and prioritising critical spare parts 
• reviewing existing designs and standards 
• evaluating suitable materials and manufacturing technologies 
• studying how spare parts can be digitalised using methods such as 3D scanning 
• developing processes for rapid spare part production in crisis and wartime situations 

The project will also explore how national additive manufacturing capabilities could complement traditional inventories and established supply chains.

Expected results

The project will deliver a prioritised list of spare parts and components considered most suitable for 3D printing. The results will also include recommendations on requirements, testing and standards, as well as a description of how spare parts could be manufactured in practice under disrupted conditions.

In the longer term, the results could contribute to greater robustness and recovery capacity in the Swedish power system by creating the conditions for national and flexible spare parts supply.