USACE 3D Prints Largest-Ever Civil Works Component for Soo Locks

As winter traditionally forces a pause on shipping through the Soo Locks, a critical passageway for maritime commerce through the Great Lakes, the U.S. Army Corps of Engineers (USACE) is leading the way in innovative maintenance solutions. This year, USACE has taken a giant leap forward in civil engineering by 3D printing the largest U.S. civil works component ever created, successfully leveraging AM to manufacture a crucial part for the Poe Lock’s ship arrestor system.

At the center of this project was the replacement of aging components, notably the lever arm for the Poe Lock’s ship arresting system, which protects the lock’s gates from runaway ships and ship collisions. Responsible for the system’s overall function, these lever arms, which had been in service for more than 60 years, had developed cracks, requiring a swift and effective solution to ensure the uninterrupted flow of maritime traffic.

The 12 foot-long 3D printed metal part installed within the arresting system of the Poe Lock. (Photo Credits: USACE)

Faced with a tight deadline and recognizing the complexity of the project, the USACE Detroit District teamed up with field experts to explore creative solutions. Years of research by the U.S. Army Engineer Research and Development Center were consulted as the decision was made to leverage 3D printing technology to speed up production while meeting the project’s strict quality requirements. In close partnership with industry leaders like Eaton Corporation and academic institutions such as the University of Toledo, USACE tapped into Lincoln Electric, a leading provider of welding solutions technology, to quickly fabricate a new lever arm using wire arc additive manufacturing (also called WAAM).