Energy systems often operate under high temperatures, pressure, and chemically demanding conditions. Components used in thermal processing, hydrogen storage, and power generation must combine material stability with efficient heat transfer, controlled flow, and reliable performance.

Advanced ceramic materials such as silicon carbide support these requirements through high thermal stability, wear resistance, and strength at elevated temperatures. Binder jetting makes it possible to create internal channels, lattice structures, and near-net-shape components that would be difficult to produce through conventional machining or forming.

The same technology also supports investment casting molds and cores, as well as washout tooling for composite hydrogen tanks. These applications reduce tooling constraints and create more flexible routes for producing complex parts across thermal, storage, and energy-generation systems.

SiSiC

For wear applications and thermal management.

Washout tooling

For hydrogen tanks and complex composite parts.

Large scale

Large, highly complex parts.

Industrial speed

Fast manufacturing at industrial scale.

Fit for purpose

Unique material properties fit for the application.

Application

SiC lattice structure

High-temperature energy systems require materials that can withstand extreme heat while maintaining performance and reliability. Applications such as heat exchangers, radiant burners, solar receivers, and nuclear systems often operate beyond the limits of conventional metallic components.

Using CONCR3DE Armadillo binder jetting printer, intricate silicon carbide lattice structures can be manufactured with highly engineered internal geometries. These open architectures maximize surface area for heat transfer while retaining the strength and thermal stability required for operation at temperatures above 1000 °C.

The combination of advanced ceramic materials and design freedom creates new opportunities for thermal management in demanding environments. Complex lattice geometries can be tailored to specific performance requirements, enabling new approaches to the design of high-temperature energy systems.

On Elephant, the larger build area allows multiple SiC lattice components to be produced in a single print, making the process suitable for applications that require consistent output at industrial scale.

Application

Investment casting

Turbine blades used in energy generation often contain intricate internal cooling channels that are essential for performance and durability. Manufacturing the molds and cores required for these components is traditionally a complex and time-consuming process, often involving dedicated tooling and long lead times.

CONCR3DE Armadillo printer enables the production of highly detailed investment casting molds and cores directly from digital designs. Binder jetting makes it possible to create complex internal geometries with high resolution, eliminating the need for tooling while supporting industrial-scale production.

By simplifying the path from design to casting, manufacturers can accelerate development cycles, reduce production costs, and produce advanced components that would be difficult or impossible to realize using conventional methods.

With Elephant, larger production runs of molds and cores can be completed within a single workflow, helping foundries move from development and validation toward continuous industrial casting production.

Application

Hydrogen tank

Hydrogen tanks must combine safety, low weight, and efficient use of materials. Type V tanks remove the need for a separate metallic or polymer liner, allowing the carbon fiber structure itself to provide both strength and containment.

CONCR3DE supports the production of these liner-less tanks through 3D printed washout mandrels. The mandrel defines the internal tank geometry during carbon fiber winding and curing, then dissolves in water to leave the finished hollow structure without conventional demolding.

For the energy sector, this approach creates new possibilities for developing hydrogen tanks with optimized internal geometries and fewer tooling constraints. It can support stationary storage, transport systems, and other hydrogen applications where repeatable production and design flexibility are important.

On Elephant, several mandrels can be produced within the same print cycle, increasing tooling output for larger hydrogen tank production programs.