Totech from Billingsfors in Dalsland, Sweden, is a provider of technical solutions in production engineering, manufacturing, and automation. For many years, the majority of their activities have been in the offshore sector. One of their products is a 6.8-kilogram aluminium hydraulic block, which we will return to. 

We have spoken to two of the key figures at Totech, who have been with the company since it was founded in the 1990s, Tommy Tveter, CEO, and Robert Aronsson, Construction Manager. These inquisitive individuals, deeply passionate about technology, quickly embraced the concept of 3D printing as it gained momentum. The idea of incorporating the technology into their work was not foreign to them when they first heard about the 3D-Action project through IUC Väst. The question was: How would they take on this endeavor? 

Better, smaller, and more agile

Following conversations with IUC Väst and RISE, along with a visit to the Application Center for Additive Manufacturing, Tommy Tveter and Robert Aronsson were certain about two things: their desire to engage in the project and their interest in experimenting with printing a hydraulic block. 

"In a typical hydraulic block, drilling is necessary, and some of the channels pose challenges. Drills tend to be straight – or at least they begin that way when you start drilling," Tommy Tveter says, with a smile.   

This was certainly one of the factors making the hydraulic block well-suited for 3D printing. But there were several other reasons behind the choice. The hydraulic block needs to withstand a harsh environment, exposed to both saltwater and corrosive drilling fluid. Enhanced corrosion resistance would therefore be desirable. But crafting the block using traditional methods, with anything other than surface-treated aluminium, would be far too heavy and costly. Yet another incentive for adopting a new manufacturing method was Totech’s challenge with extreme delivery times for components, occasionally reaching up to 400 working days.  

"We have now had the opportunity to carefully consider the design of the block and eliminate quite a few components, making it better, smaller, and more agile. Printing it in stainless steel provides a significant advantage due to its heightened resistance. If we had produced the old block in stainless steel, it likely would have weighed approximately 15 kilograms. However, the newly printed block weighs only 2.4 kilograms, just a third of the weight of the current block," says Tommy Tveter. 

Seeing multiple applications

During the final stages of the project, the hydraulic block was successfully printed at Chalmers University of Technology. Totech’s involvement in 3D-Action has opened up a new chapter for the company. They've received a research and development grant from the Västra Götaland Region to extend their exploration into additive manufacturing. Tommy Tveter and Robert Aronsson are optimistic and aspire to print additional components in the future, surpassing the qualities of their conventionally manufactured counterparts. 

"While the printed block is associated with hydraulics, we're also involved in pneumatics. Pneumatics doesn't entail lengthy lead times, but it demands a considerable amount of assembly time. Currently, we have to machine an aluminium box to house everything, as pneumatic components aren't designed for corrosive environments. The production of the box comes with costs, including hoses and other materials. I believe we could potentially 3D print a significant portion of this instead," says Robert Aronsson and continues: 

"This marks our path forward. By 3D printing components, we gain increased flexibility and the capability to produce items that would be challenging to make using conventional manufacturing methods. It might even open avenues for accomplishing things that would otherwise be deemed impossible."

The project was an enabler

According to Tommy Tveter and Robert Aronsson, participation in 3D-Action has been crucial for the progress they have made in 3D printing.  

"If not for the project, we wouldn't have undertaken this. The chance to collaborate on ideas with IUC Väst and RISE, along with visiting the AM facility in Mölndal, has been indispensable. Surveying the various printing methods and examining the produced parts as we walked around allowed us to grasp the realm of possibilities," states Tommy Tveter. 

For other small and medium-sized enterprises (SMEs) with products that might be suitable for 3D printing, Tommy Tveter and Robert Aronsson offer the following advice: 

"Courage is essential. Success isn't guaranteed, but without trying, you'll never find out. Paying a visit to the Application Center of Additive Manufacturing is highly beneficial for gaining insights into the techniques, possibilities, and available resources. As you explore and observe, you can connect everything to your own business, that's when innovative ideas emerge. While many may associate 3D printing with hobby use, its capabilities extend far beyond that perception."

Offshore wind power is one of the most promising options for renewable electricity generation, and Sweden has great resource potential. As wind turbines become larger, the cost per kilowatt hour (KWh) produced decreases significantly.

According to the Swedish Energy Agency, Sweden’s total electricity consumption amounted to 140 terawatt hours (TWh) in 2022.

“The offshore wind power sites currently planned along the Swedish coast amount to 90 gigawatts (GW) of installed power,” says Nermina Saracevic, Senior Project Manager for Renewable Offshore Energy at RISE. “Most of these projects are in the application stage. If just half of them are implemented, it can cover all of Sweden’s current electricity needs.”

Overlapping interests create potential risks

The growing need for fossil free energy and the increasing establishment of offshore wind farms highlight the conflicting interests that exist between shipping, commercial fishing, environmental protection, and the production of renewable energy.

The permit process when developing new wind farms is complex and involves several state and regional authorities. On behalf of various project developers, RISE analyses potential nautical risks in the establishment and operation of wind farms. These are presented together with proposals for risk mitigation measures, which are then reviewed by the Swedish Maritime Administration, the Swedish Transport Agency, and other relevant stakeholders.

“When wind turbines are planned in areas with established shipping and fishing, new risks are created, and these need to be identified and minimised,” says Christian Schell, Head of Strategic Development – Maritime Environment, Risk and Operation at RISE. “RISE is an independent partner that supports a growing industry.”

 “A lot revolves around ensuring that there are sufficient margins between shipping lanes and the wind farm, while at the same time considering both the marine environment in general and national, commercial fishing. We have well-established methodology for investigating maritime traffic patterns, as well as proven calculation programs for calculating the probability of allisions, collisions and groundings. The current increase in applications requires an overview of the cumulative effects of the establishment of new offshore wind farms, along with their impact on ship traffic and the marine environment.”

Upgrading of Nordic ports

The permit process for offshore wind farms can take between 7 and 10 years and requires several different stakeholders to approve the project for it to become a reality. In addition, port infrastructure and supply chains need to be adapted, as their role in a future offshore wind establishment will be significant both in the short and long terms.

RISE, via the cluster platform OffshoreVäst, is leading the Swedish part of the NOW PORTS project. It aims to support Nordic ports in ensuring adequate surfaces and quays, and that expertise is in place to create an optimal supply chain when establishing and operating offshore wind power.

The project is a joint initiative where Sweden, Norway, and Denmark collaborate on issues related to future ports and offshore wind industry.

“In addition to infrastructure issues, Swedish wind power stakeholders have indicated a need for a national coordinator who can facilitate the development of offshore wind power between different authorities, as well as regional and local politicians who have an impact on the permit process,” says Nermina Saracevic, Project Manager of NOW PORTS at RISE. “As a neutral party, RISE can assume that role.”

Risk analyses, consultation, and testing

RISE offers expertise throughout the life cycle – from pre-analyses of a proposed establishment site to decommissioning and recycling of end-of-life turbines. We possess a significant pool of expertise in the area to support this, as well as test facilities for floating wind turbines, CFD analysis for wind, and hydrodynamic design and verification.

“Today, RISE is entrusted by the majority of project developers in Sweden, where various services, such as nautical risk analyses, consultation, and testing and verification constitute some of the largest service areas,” says Christian Schell. “RISE’s experts have delivered to all major projects that have received permits from the government. Commercial offers in combination with scientific research position RISE as a strong and valuable partner to the operators who are actively pushing for the establishment of offshore wind power in Scandinavia.”