Industrial valve body SLS production part.
Case study: SLS 3D printing of a complex industrial valve body for a Perth-based mining equipment OEM — replacing a multi-part assembly with a single SLS-printed nylon component, eliminating 14 separate machined parts and assembly time.
Project overview
A Perth-based mining equipment OEM engaged ASTCAD to redesign a complex valve body that had previously been a 14-part machined-and-assembled component. The redesigned single-piece SLS nylon part incorporates internal flow channels, integrated mounting features and threaded inserts in a single print operation.
The challenge
The original assembly had 14 machined components with 8 different sealing surfaces — costly to manufacture and prone to leak-path failures. The customer needed equivalent or better performance, equivalent cost, and elimination of the assembly labour without compromising the equipment certification.
Our approach
- Design consolidation — 14 parts to 1 single SLS-printed component
- Internal flow channel design with optimised flow geometry
- Threaded insert integration during print process
- SLS material selection (PA12) for chemical compatibility and strength
- Pressure testing and certification documentation
Deliverables
- Production-validated SLS valve body design
- Manufacturing dossier with print parameters and QC protocol
- Pressure test certification per ISO 5208
- Cost comparison vs. original 14-part assembly
- Field service documentation for replacement units
Outcome
Manufacturing cost reduced by 32% per unit. Assembly labour eliminated entirely. Field reliability data after 18 months in service shows zero leak-path failures across 240 units installed. The customer has migrated four other valve sizes to the same SLS-printed design.