Additive manufacturing presents a significant opportunity for the energy industry, dramatically reducing lead times for critical valve components while enabling advanced design enhancements that improve performance and reliability. However, converting legacy valve designs into additive-manufactured components is not without challenges—it requires significant engineering expertise and a rigorous development process. This presentation explores the transformation of a legacy maritime steam valve, in service for over three decades, into an advanced additive-manufactured solution. The original valve suffered from persistent leakage issues and inadequate product support, forcing costly and disruptive ship maintenance. With limited product documentation available, the development team leveraged detailed investigation, advanced engineering analysis, and validation testing to overcome these barriers. The result: a redesigned valve that enhances reliability, simplifies maintenance, and reduces operational downtime. We will share key insights from this development journey, highlighting the technical and operational challenges of implementing additive manufacturing in critical applications. The session concludes with a discussion on adoption hurdles and the broader potential of additive technology to modernise industrial valve solutions across the energy and maritime sectors.