Case Study: QualiCal achieves major downtime reduction and increased revenue with Materialise 3D‑printed METRO

Qualical’s Metro Puts 3d Printing In The Limelight

QualiCal, an Italian engineering firm, faced recurring failures and costly unplanned downtime from traditional shaft level indicators (SLIs) used in lime kilns. To upgrade its METRO SLI prototype and exploit Industry 4.0 benefits, QualiCal partnered with Materialise to apply 3D‑printing design techniques and high‑performance materials to overcome clogging, friction failures and complex mechanical parts.

Materialise redesigned the METRO using 3D‑printed fiber/aluminium‑reinforced nylon with honeycomb structures, halving the drum diameter (500 mm to 250 mm), removing hydraulics and adding front‑to‑back screw channels to prevent dust ingress. In a six‑month pilot the unit required no maintenance, improved sensor accuracy, eliminated gearbox lubrication and matched the production cost of traditional SLIs—projected to save roughly €120,000 per year per plant and potentially increase revenue by up to €1,400,000 over the equipment’s lifetime.

QualiCal

Carlo Cella

Chief Executive Officer