Servogear, a provider of propulsion systems, needed a custom flange solution to address persistent overheating in their electric motor during high-demand operations.
The standard flange between the diesel engine and electric motor did not deliver sufficient cooling, causing frequent overheating and risking operational disruption—especially during extended use in boost mode.
Using Laser Powder Bed Fusion (LPBF) in aluminium, the flange was redesigned to integrate passive cooling fins based on topological optimization. This increased the surface area, improving heat dissipation and overall system performance. The switch to aluminium also reduced weight significantly.
“I am impressed by the remarkable durability of the additively manufactured flange we recently installed. It withstood continuous operation in boost mode for an unprecedented 1.5 hours. The quality of this flange has surpassed our expectations, setting a new benchmark for cooling performance. We’re excited about the possibilities of additive manufacturing in future projects.”
– Malvin Teigland, Service Manager, Servogear
This case demonstrates how on-demand manufacturing empowers OEMs to tackle persistent performance issues with highly customized, engineering-led solutions. By combining design freedom, material optimization, and rapid turnaround, additive manufacturing unlocks new levels of reliability and responsiveness—especially for critical systems under thermal stress.