Challenges:
The traditional method for wax injection tool requires weeks and tens of thousands of dollars to finish. Before the design is confirmed, it has to go through extensive cycle analysis, computational fluid dynamics, finite element analysis and solid modeling but there’s always chance that alternations may be required due to mistake or change in specification. If there’s design change, the new test part will be an expensive, time-eating piece of scrap.
In addition, with traditional techniques, iterative design and testing become virtually impossible. Especially for turbine blades may require several tests as they have to be twisted precisely. Even a few degrees off and they won’t be able to function. When one part costs from $20,000 onwards, it is not feasible to produce several parts for testing alone.
“If we used a traditional method for a wax injection tool,” says Toby Kutrieb, “it could take up to 5 weeks and cost well in excess of $20,000. However, if we rapid prototype an axial turbine blisk, for example, with our 3D Systems printer, the investment piece builds unattended overnight and is ready for foundry in the morning for well under $2,000.”
Solutions:
Wisconsin-based Turbine Technologies and its gas turbine development sister company, Kutrieb Research, found the solutions to make changes and maximize iterative design by producing parts quickly, accurately and at a lower cost with 3D Systems ProJet MJP Wax 3D printing 
technology. They produce multiple wax patterns which they will then cast in superalloys and test until they find the right design.
Benefits:
The ProJet is also allowing the company to branch out in terms of offerings and product variation. One of its educational pump labs allows engineering students to learn about impellers by designing their own. Turbine Technologies then uses the ProJet to produce each student’s design. “They design the impeller, mathematically figure out what it will do. Then they send us a design file, we print it, cast it and the student can see how close their predictions were,” says Toby Kutrieb. It’s extra offerings like these that bolster the Turbine Technologies brand and enhance the educational experience for students all over the world.
Today, many of the internal parts of the turbines produced by Turbine Technologies and Kutrieb Research 3D printed first on the ProJet. They’re even doing some service work on the side for area companies that don’t have the same casting and rapid prototyping technologies. Through it all, with the help of their streamlined workflow, the Kutrieb family companies have bolstered their standing as trusted turbine developers and manufacturers, and they’ve charted further into the future with bold new designs for the larger engine market.