3D Printing for Heavy Engineering

Solving Complex Engineering Challenges with Industrial 3D Printing

From prototyping massive components to producing durable end-use metal parts, Sahas supports the heavy engineering sector with scalable 3D printing, custom tooling, and rapid part replacement; all with unmatched precision and turnaround.

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3D Printing Applications in the Automotive Industry

Large-Scale Prototyping
Tooling & Fixtures
End-Use Metal Parts
Spare Parts & Maintenance
Hydraulic & Pneumatic Systems
Heat Exchangers & Cooling
Industrial System Optimization

Large-Scale Prototyping

  • Pump Casing Mockups
  • Compressor Housing Models
  • Gearbox body casings
  • Turbine shell prototypes

Tooling & Fixtures

  • Assembly Jigs
  • Welding & Inspection Fixtures
  • Custom drill guides
  • Heavy-duty clamping and positioning tools

End-Use Metal Parts

  • Pump Impellers
  • Turbine Blades
  • Custom couplings
  • Structural connectors for industrial machines

Spare Parts & Maintenance

  • Gearbox Covers
  • Obsolete Equipment Parts
  • Flange covers and dust shields
  • Replacement panels and brackets

Hydraulic & Pneumatic Systems

  • Custom Valves & Connectors
  • Air & Fluid Control Blocks
  • Mounting brackets for hydraulic units
  • Pressure-regulating system components

Heat Exchangers & Cooling

  • Conformal Heat Exchangers
  • Cooling Fins & Ducts
  • Manifold components
  • Compact radiator blocks

Industrial System Optimization

  • Lattice-structured parts for weight reduction
  • Flow-optimised internal geometries
  • Redesigns for improved thermal performance
  • Reduced-part-count assemblies

Frequently Asked Questions

Technologies like FDM, Binder Jetting, and SLA are used to create large functional prototypes for fit, ergonomics, and design validation—reducing development time and cost.

Yes, industrial-grade FDM and SLS are ideal for producing custom jigs, assembly fixtures, and handling tools that are cost-effective and optimized for shop floor operations.

Metal 3D printing (DMLS/LPBF) delivers high-strength, fully dense parts in alloys like Inconel, stainless steel, and tool steel—suitable for demanding mechanical environments.

On-demand 3D printing eliminates the need for high inventory costs by producing critical spares quickly, especially for obsolete or low-volume parts in legacy equipment.

Yes, 3D printing is used to manufacture custom manifolds, brackets, and fluid handling components with internal channels—especially using metal AM and high-strength polymers.

Metal 3D printing enables the production of complex heat exchangers with conformal cooling channels and optimized geometry for improved thermal efficiency in compact form factors.

Additive manufacturing allows lightweighting, performance tuning, and design consolidation—leading to reduced part count, improved efficiency, and faster production cycles.

FDM and Binder Jetting are ideal for large-format plastic and sand molds, while DMLS and DED (Directed Energy Deposition) are used for high-strength, load-bearing metal parts.

Yes, through 3D scanning and reverse engineering, we can recreate CAD models of obsolete parts and manufacture them using appropriate additive or subtractive processes.

3D printing reduces downtime, lowers tooling costs, accelerates prototyping, and enables customization—all of which improve operational efficiency in industrial settings.