Achieving the highest quality standards is crucial in the aviation industry, where even the smallest of defects can have serious consequences. Besides the expansion of e-mobility, one of the most important recent developments in this field is the ability to produce components using additive manufacturing.
This is particularly beneficial in the aviation sector, where every single gram of weight saved can reduce flight operating costs. This is why toolcraft not only produces aircraft parts conventionally using CNC machining, but employs additive manufacturing processes as well. The company covers the complete process chain, from design and manufacture to quality assurance and testing. 3D metal printing has been an established manufacturing technique in its own right for many years, having successfully made the transition from being used for prototype production. Nadcap certification of the process is a further milestone in its development.
Boeing is co-operating with Swiss engineering group Oerlikon to jointly develop additive manufacturing processes in a bid to accelerate the technology’s wider employment.
Oerlikon says it signed a five-year collaboration agreement with the US airframer to create “standard materials and processes” for the production of “structural” titanium components through 3D printing.
“The research will initially focus on industrialising titanium powder bed fusion additive manufacturing and ensuring parts made with this process meet the flight requirements of the US Federal Aviation Administration and Department of Defense,” says Oerlikon.
Vanguard of the additive manufacturing industry Stratasys has seen its 3D printing technology take off in the form of in-flight parts on aeroplanes, and in June 2017 the company conquered additive manufacturing in aerospace by launching its Fortus 900mc Aircraft Interiors Certification Solution.
There is much more to additive manufacturing for aerospace than getting parts approved by the OEM for installation in a working aircraft. Eric Bredin, Vice-President Marketing EMEA for Stratasys, set out just what it takes to get a Stratasys-printed machine into the lower stratosphere.
“In general, aerospace is a very interesting segment as it’s a market in which we have a lot to play with,” he explained. “What we are trying to influence is concept design right through to production and there are many areas in this industry where we can be very active.”
Latécoère is deploying Stratasys FDM additive manufacturing throughout its design and production process.
French aircraft design and manufacturing group Latécoère is deploying Stratasys FDM additive manufacturing throughout its design and production process. Latécoère – which services aerospace giants including Airbus, Bombardier and Dassault – is using its Stratasys Fortus 450mc Production 3D Printer for both rapid prototyping and production tooling. According to Simon Rieu, composite and additive manufacturing manager at Latécoère’s R&D and Innovation Center, the adoption of this technology has been transformational for both design and manufacturing.
“Additive manufacturing has integrated seamlessly into our design and production process, and has seen us enjoy improved lead-times, reduced costs and enhanced operational efficiency,” he says. “As the requirements of the aerospace industry become more demanding, we’re also mindful of the need to maintain our competitive edge, and Stratasys additive manufacturing enables us to meet that objective.”
Emirates has for the first time used cutting-edge 3D printing technology to manufacture components for its aircraft cabins.
The airline used Selective Laser Sintering (SLS), a new 3D printing technique to produce video monitor shrouds.
Emirates has worked with 3D Systems, a US based 3D printing equipment and material manufacturer and services provider, and with UUDS, a European aviation Engineering and Certification Office and Services Provider based in France, to successfully print the first batch of 3D printed video monitor shrouds using 3D Systems’ Selective Laser Sintering (SLS) technology platform.
The airline has also 3D printed, received certification for and installed aircraft cabin air vent grills for on-board trials in its first class cabins.
On the ground floor of 3D printing technology for years, aerospace manufacturers first began adopting the various additive manufacturing (AM) processes for use in prototyping. With each advance in the technology, they have been there as AM was used for the creation of tooling to, most recently, the mass manufacturing of end parts.
GE increased its role in the industry dramatically when it acquired two metal 3D printer manufacturers and formed GE Additive. GE, however, isn’t the only aerospace company that’s taken AM to the skies. Also ahead of the pack is Boeing, which has been flying 3D-printed parts since 2003.
North American 3D printer manufacturer Stratasys is supporting the development of the “world’s first all-electric commuter plane,” while Belgian 3D printing company Materialise has a key role in the development of an electric race car.
Based in Israel, Eviation Aircraft is racing to complete development of its ‘Alice Commuter’ to be the first all-electric commuter plane in the skies. To do so, the company has incorporated 3D printing to speed up development and reduce costs.
Constituting of Eindhoven University of Technology students, InMotion’s incentive to implement 3D printing is to reduce weight in all of its races. Using Materialise’s 3D printing services, InMotion has incorporated crucial metal parts in its IM/e racecar.
The aerospace industry has so fully embraced 3D printing that it will undoubtedly work to resolve any challenges.
If you fly in a plane in the next few years, you are statistically likely to be flying in one that contains 3D-printed parts, also known as parts made via additive manufacturing (AM). While Stratasys says 3D printing is great for interior parts, Airbus announced plans to 3D-print 30 tons of metal parts every month by 2018. Some of them will be the brackets and structural parts that hold the plane together. In fact, aerospace manufacturers are working 3D-printed parts into just about every facet of the plane, including engine parts.
General Electric (GE), for example, is planning to mass-produce 25,000 LEAP engine nozzles with 3D printing. According to a ReportsnReports study, “The Global Aerospace 3D Printing Market to Grow at 55.85% CAGR during the period 2016–2020,” the primary driver of 3D printing in the aerospace market is the miniaturization of jet engines. The more widely additive manufacturing is used, however, the more issues come to light—ranging from the price of powders and resins to potential supply-chain weaknesses. Yet the aerospace industry has so fully embraced 3D printing that it will undoubtedly support the resolution of such problems.
Mouser Electronics Inc. and Grant Imahara have announced the winning design in the International Space Station (I.S.S.) Design Challenge has been 3D printed in space.
Andy Filo, an engineer based in Cupertino, designed the satellite-launching device that is now in orbit. It is hoped that eventually the 3D printed device for the testing and deployment of Femto Satellites for the Internet of Space may be used by astronauts on missions.
The challenge set was to “help astronauts aboard the International Space Station with a device that improves their jobs or daily life.” As previously reported by 3D Printing Industry, Mouser Electronics Inc are frequent sponsors of such challenges. The satellite-launching device was 3D printed using Made In Space’s Additive Manufacturing Facility (AMF), who recently told us more about how 3D printing is advancing the space industry.
The aerospace industry has quickly found the utility in 3D printing items, both in reducing the cost of making parts themselves and in the cost reduction of operating aircraft with 3D printed parts, through the reductions in emissions and fuel use by having optimized designs. With Boeing now using the technology in its Dreamliner, we can safely say that 3D printing is no longer just for prototyping, and is part of the manufacturing mix!
The move will reduce production costs for each Dreamliner by $2M to $3M
Boeing will begin using at least four 3D-printed titanium parts to construct its 787 Dreamliner aircraft and may some day rely on as many as 1,000 parts created via additive manufacturing.
Boeing has hired Oslo, Norway-based Norsk Titanium AS to print the parts. It marks the first time that FAA-approved, 3D-printed titanium parts will be used as structural components on a commercial aircraft, according to the company.
The parts will be used near the rear of the Dreamliner, a mid-sized, wide-body, twin-engine jet airliner. Boeing builds about 144 Dreamliners each year.