Hyliion's KARNO Technology: A Case Study in Metal Additive Manufacturing

Problem: Transitioning from Prototyping to Commercial Production

Hyliion, a publicly listed manufacturer specializing in clean modular power generation systems, faced a significant challenge in transitioning from the prototyping phase to full-scale commercial production for its flagship KARNO technology. Acquired from GE Aerospace in 2022, the KARNO Generator technology was initially developed using metal additive manufacturing (AM). However, scaling up this technology for mass production posed several hurdles, including the need for a robust and efficient manufacturing workflow.

Solution: Scaling Up with a Fleet of Metal AM Systems

To address these challenges, Hyliion invested in a substantial metal additive manufacturing capacity, which has since become a cornerstone of its production strategy. This investment was not merely about expanding the number of machines but also about refining the entire AM workflow to ensure efficiency and reliability. According to Hyliion CEO Thomas Healy, the company has scaled up to a fleet of three dozen Metal AM systems, which are now integral to the production of the KARNO 200 kilowatt power module.

"We wouldn't have a product without additive," Healy stated during a recent episode of the Additive Insight podcast. "The capabilities of KARNO are deeply intertwined with the advantages that metal additive manufacturing offers."

The KARNO 200 kilowatt power module, a key commercial product, exemplifies the successful application of this technology. The use of AM has allowed Hyliion to achieve complex geometries and material properties that would be difficult, if not impossible, to achieve through traditional manufacturing methods.

Results: Enhanced Capabilities and Future Potential

The deployment of a large-scale metal AM fleet has yielded significant benefits for Hyliion. Firstly, it has enabled the company to maintain a high level of precision and quality control, which is crucial for the performance and reliability of the KARNO technology. Secondly, the flexibility of AM has allowed Hyliion to iterate and improve its designs more rapidly, accelerating the product development cycle.

Moreover, the scalability of the AM workflow has positioned Hyliion to meet growing market demands. As Healy noted, the company expects to further evolve its application of additive manufacturing, potentially expanding its use to other product lines and exploring new materials and processes.

"The potential for additive manufacturing is immense," Healy emphasized. "As we continue to innovate and push the boundaries of what's possible, we see even more opportunities to leverage this technology."

##