How to get ahead of competitors: SIBUR develops additive manufacturing

Sibur engineer Roman Tikhonov (right) and Ivan Papusha, head of 3D at iQB Technologies. With the support of our company, programs have been developed for training specialists at SIBUR additive centers.

So far, there are few specialists like Roman Tikhonov in Russia. Roman leads the center for the introduction of 3D technology at the Voronezhsintezkauchuk enterprise, which is part of the largest Russian petrochemical company SIBUR Holding. The company has production branches in more than 20 cities of Russia and is engaged in the production and supply of petrochemical products for the domestic market and 80 foreign countries. A pilot project recently launched in Voronezh as part of SIBUR’s global digitalization has already shown excellent results. Roman spoke about specific examples of solving problems using 3D printing and 3D scanning at his enterprise and shared his vision of the prospects for introducing such innovations in Russia.

- Tell us a little about yourself. What brings you to the additive industry?

- Interest in something new, I guess. I have always been fascinated by innovation. I am a microelectronics engineer by training, I was engaged in information technology, and it so happened that the next project in which I got involved is connected with additive manufacturing.

I have been working at SIBUR relatively recently, there is not even a year. Before that, for about five years he took part in one pilot project to introduce additive technologies, and then received an invitation to Voronezhsintezkauchuk.

- How long has SIBUR been introducing 3D technology? At what stage is the additive center project?

- The company became interested in this topic two years ago. We began to collect information, to study use cases. The specifics of chemical enterprises is such that most of the equipment is classified as especially dangerous, and no errors or emergency situations are permissible in principle. We came to the conclusion that it is cost-effective to apply these technologies in the repair industry. An additive center was created at the Voronezhsintezkauchuk enterprise, a 3D scanner and a 3D printer were purchased, and I was invited to lead them.

We already have working cases that have shown excellent results both in 3D printing of products and in implementation in the production process. We have confirmed in practice that additive technologies allow us to quickly produce parts and assemblies and minimize downtime.
After that, it was decided to open such centers at seven more enterprises with repair facilities - where maintenance and restoration of equipment is required.

Now there is a purchase of equipment and software, staffing. So far, the emphasis is on 3D printing with plastics and on 3D scanning for reverse engineering of failed products.

Additive technologists save the SIBUR core fund due to the fact that a number of tasks are solved on their own

- What competencies should an additive center specialist have? How is the selection and training of staff?

- Training programs already exist, they are developed with the support of iQB Technologies. First of all, they will be designers with experience in designing in mechanical engineering. We understand that in Russia there are very few 3D-technology specialists, and, of course, we will give preference to those who have an idea of ​​3D-printing and 3D-scanning. In any case, we will train them. I myself, as a designer, gradually accumulated and improved knowledge, and then applied them in practice.

- How many employees work in one center?

- At the stage of launching the project, one or two, depending on the territorial location, size of the enterprise and the range of tasks. Now I am engaged in modeling, scanning, and printing alone. Since there are positive results, a decision has already been made to expand the staff. In addition, we work with several organizations involved in 3D printing. They carry out orders for those technologies that we do not have yet.



Bypass roller conveyor belt
Using CAD-systems designed 3D-model.
The diameter is increased, the mounting holes for bearings are strengthened (weak spots of the original part).
The original was made of steel, using FDM printing with ABS plastic it was possible to reduce the weight of the product, solve the problem of sticking briquettes on the line and minimize the possibility of damage to the packaging film.

- Can you give an example of the successful implementation of 3D printing in the production process?

- It all starts with popularization. As soon as people working at SIBUR's facilities understand what 3D printing is, they begin to wonder how it can be applied. I’ll tell you about a solution implemented on one of these appeals. A rubber product in briquettes goes through the conveyor, which are then packed into a film. Periodically, the briquettes stuck on the metal bypass of the conveyor belt, as the bearing seat collapsed due to the constant load. A mechanic turned to us - is it possible to make this part from plastic (since it is long and expensive from metal), and also increase the diameter to avoid jamming? The problem was successfully solved with the help of an FDM printer, everything works fine. Plus, the video itself turned out to be light, as it was designed with internal channels.

In the forecasts - the creation of at least one center of additive technologies at each of the 23 SIBUR enterprises

- How do you calculate the economic effect?

- We cannot calculate exactly yet, here, first of all, the effect of the speed of execution. But take the above case. In fact, a kilogram of plastic was spent on a roller - metal would definitely be more expensive. At the enterprise level, this is a saving of millionths of a percent. But if this briquette on the conveyor was scratched by a failed roller, it immediately goes to marriage. The second time you can’t pack it and sell it. And if you calculate how much is rejected per year, the losses from this video grow to incredible amounts.

Another example is the impeller of a centrifugal pump. Such wheels are naturally made of stainless steel. But under the influence of the pumped liquid, they quickly fail. A 3D model of the impeller was created, then printed on a 3D printer made of polyamide (SLS technology). There was no degradation for a month of work, in principle, unlike a stainless steel that it “eats” right before our eyes.



Centrifugal impeller
Using a 3D scanner and CAD systems, a 3D model has been designed for alignment of geometric dimensions.
Based on the 3D model using the technology of selective laser sintering (SLS) of polyamide powder, an impeller is made. The original is made of stainless steel, there is a strong degradation.

A similar problem, which was solved using 3D printing, was the manufacture of the pump impeller from polyurethane instead of stainless steel, it also underwent severe degradation. The new wheel provides the same performance as the original, but thanks to the plastic, degradation is completely absent.

- As you can see, printing on a 3D printer of finished parts gives a clear benefit. Do you do prototyping?

- Yes, for example, we worked out one of the variants of the impeller. A prototype was printed from ABS plasticinstead of a completely failed product. The original wheel crumbled in the pump, it was literally assembled in parts, scanned, performed reverse engineering. Then they printed a prototype and sent it to the repair shop. Why is it more profitable than classical methods? No one will cast such an impeller in a single copy. And if we order 20-30 pieces of stainless steel, and it does not fit, it will be a fiasco.



Pump impeller
Made of polyurethane by vacuum casting with a metal insert.
The original is made of stainless steel, severe degradation is observed.

- With the help of additive technologies do you solve only single production problems?

- Not only. We supply rubber to leading manufacturers such as Michelin, Pirelli, and one of their requirements is perfect geometry. For this, the line was equipped with an automated system of optical sensors for geometry control . Japanese sensors, each worth tens of thousands of rubles. To avoid possible damage, we decided to provide them with protective cases. Right at the enterprise they tried to make metal cases - it is expensive, first of all, due to labor costs. We turned to our department, and we printed the first 20 pieces from ABS plastic. The whole line is 200 sensors, the FDM printer prints two housings per shift. Thus, thanks to 3D printing in 100 shifts, the task will be completed.

- A great example of small-scale additive manufacturing! Do you use only FDM technology?

- Now - yes, so far only this equipment has been purchased. The main advantages of FDM printers are the availability and a wide range of materials that are advantageous to use for various properties.

- Do you consider other 3D printing methods?

- We plan to purchase a stereolithographic 3D printer that prints with polyamide. I have already mentioned the creation of finished products from polyamide - this solution completely satisfied us. 3D metal printing is out of the question: in the realities of Russian business today, it can be done either by defense enterprises or research institutes. Large investments are required, and a lot of time will be spent only on experiments.

With a 3D scanner, the entire process of reverse engineering, up to the start of production, is several times faster

- What are the advantages of a 3D scanner for your enterprise?

- We are mainly engaged in reverse engineering of imported components that have failed. As part of import substitution, we can reproduce parts whose delivery is problematic due to long lead times, high cost, or for other reasons, for example, related to sanctions. As a variant of a real case, using 3D-scanning and subsequent reverse engineering, we make drive stars for the conveyor.



Conveyor belt gear
Using a 3D scanner and CAD systems, a 3D model has been designed to restore the original geometric dimensions.
The test batch was made of ABS plastic using the FDM printing method; successful tests were passed.

We also use 3D scanning for reverse engineering of integral parts, which we then manufacture on our own using the classical method. With a 3D scanner, the whole process, up to the start of production, is several times faster.

- How to convince business leaders and business owners that 3D technologies are effective?

- To prove to people the need to introduce 3D technologies is the most difficult. The involvement, initiative of decision makers is important. Say, we managed to create an additive center at our enterprise largely thanks to the chief engineer Maxim Nikolaevich Lenkov, whose initiative found support from the top management.

I have been working for the company for nine months, and we began to actively introduce additive technologies more than six months ago. As already mentioned, we are not yet ready to consider the economic effect. But the examples given above save the main fund due to the fact that a number of tasks are solved on their own. The spacer sleeve of the pump was printed on a 3D printer. In the event of a breakdown of the primary and backup pumps, this pump can be recovered five times. Such examples cannot but convince.



Spacer sleeve
Source material is polyurethane. The original product underwent almost complete mechanical deformation. The creation of a 3D model was carried out according to the response parts of the mechanism. The prototype for test tests, including geometrical deviations, was made of ABS plastic by the FDM method.

At the same time, there is an understanding: if 3D technologies are successfully implemented, it means that they must be mastered, or at least be in the know about innovations. Manufacturers who develop new competencies in this direction will not share them. They will move to a new level, and who did not have time to rebuild will be uncompetitive.

- How do you assess the prospects for the development of 3D-technologies in Russia in the coming years?

- Let's start with SIBUR. I think that during 2019 pilot projects of additive centers at enterprises will show effectiveness, and in the forecasts - the creation of at least one such center at each of 23 enterprises.

If we talk about Russia as a whole, everything is complicated. Until there are normative acts, the situation will not change radically. Now, decisions on the introduction of additive technologies are being made at the level of managers of individual enterprises. As soon as the issue with regulatory legislation is resolved, I am sure there will be a sharp jump. Mass development will begin, as it will be possible to freely commission certified products.

We are five to seven years behind developed countries from additive manufacturing. We lag behind both financially and in terms of introducing technology into the production process. Until we recognize the need for 3D technology and break stereotypes, there will be no mass adoption. SIBUR is setting a positive example, and I am sure that other companies will adopt our experience. They will see what we have achieved and will ask themselves a question - why not try it at home?