Epiroc and SSAB are exploring new alternatives to conventional manufacturing of OEM parts and spares that offer the
potential of shorter lead times, better availability, reduced transportation costs and a smaller environmental footprint.

The initial step in the process has been to create a prototype of a hydraulic block for a mining rock drill using additive technology with conventional steel powder. Traditional manufacturing with milling and drilling requires this type of part to be plugged and sealed after production. When using additive manufacturing, six potential points of leakage can be eliminated. It is also possible to improve hydraulic oil flow since sharp edges can be avoided when the channels are printed in the part.

While traditional manufacturing uses a block of steel weighing approximately 50 kg (110 lb), the optimized design for additive manufacturing uses 7.5 kg of steel for producing this part. This reduces the amount of material needed for production with 85% in this case, which leads to more efficient use of raw materials. The weight of the end-product is also significantly lower: In traditional manufacturing the part weighs 15 kg after manufacturing; the optimized design together with additive manufacturing makes the part weigh 6.6 kg after production. This reduces the weight by 55%.

As rock drills are positioned far out on the feed of the drill rig, their weight has a substantial impact and new technology opens the possibility to create stronger components without affecting the balance of the machine. Reduced weight on the feed could also improve the lifetime of other components due to the reduction of stress and load, according to Epiroc.

With the prototype successfully produced with additive manufacturing, the next step in the process is to experiment with fossil-free steel powder.