Case Study: GE Renewable Energy accelerates wind turbine casting with ExOne’s Advanced Casting Cell

GE Renewable Energy cuts wind turbine mold lead time from 10 weeks to 2 with ExOne

GE Renewable Energy, a global leader in renewable energy, faced a challenge in producing massive cast components for its Haliade-X offshore wind turbine. The conventional process of creating molds for these 60-ton parts was time-consuming, taking ten weeks or more, and shipping the finished castings was costly. To address this, GE partnered with ExOne and the Fraunhofer Institute to develop a solution.

ExOne implemented its large-format sand binder jetting technology, creating the Advanced Casting Cell (ACC) based on its S-9000 platform. This massive 3D printer streamlined mold production, slashing lead times from ten weeks to just two. The solution improved casting quality and enabled localized manufacturing, removing the need for long-distance transport. The project received significant funding and is poised to reduce hydropower costs by 20% and lead times by four months.

GE Renewable Energy