FDM 3D printing proves better than traditional manufacturing in this latest case study from Moog Aircraft Group (NYSE:MOG.A) and leading Stratsys reseller SYS Systems.
As a solution for spare parts and tooling, fused deposition modeling (FDM) is the 3D printing technology of choice for cutting costs and lead times at factories around the world. In recent news, Ricoh opted to switch out metal for FDM 3D printed plasticsat an assembly factory in Japan. And Spain’s Indaero won a lucrative Airbus contract on the back of its FDM part production.
The Moog Aircraft Group is already a key part of the supply chain for many aerospace/defence companies including Lockheed Martin, Boeing, Airbus and Northrop Grumman. In collaboration with SYS Systems, Moog identified FDM 3D printing as the best solution for producing bespoke fixtures, used in the machines that qualify aerospace-grade parts.
South African biotech startup Akili Labs has developed FieldLab, an accurate, affordable and portable 3D printed diagnostics lab that can cost as little as $1,500, or one-tenth of similar equipment.
The FieldLab was created by Akili Labs co-founders and Rhodes University Biotechnology Innovation Centre (RUBIC) graduate students Charles Faul and Lucas Lotter. Their aim is to give doctors and scientists a rapid and accurate means of identifying disease outbreaks on the spot.
The FieldLab in a box
FieldLab is a rapid field-testing “lab-in-a-box.” It allows medical professionals in remote areas and conflict zones to access equipment typically found in state-of-the-art diagnostic laboratories. By testing for certain viruses, bacteria, and fungi on site, they can quickly identify an outbreak of disease and take the necessary measures before it spreads and becomes an epidemic.
US Nuclear Energy company Westinghouse has announced that it will be installing an additively manufactured fuel component by 2018. In doing so, it hopes to be the first company to do so for a commercial reactor.
The part in question will be a thimble plugging device, and its manufacturing and eventual installation will follow muliple simultaneous research and development into reducing costs for 3D printing obsolete components, fuel structural devices and prototypes.
The R&D projects include both internal research into 3D printed parts and two projects funded by the US Department of Energy.
3D printed drone technology has been an emerging area over the past year, with military surveillance use seeing a particular boom.
To add to the recent developments in drone delivery systems and swarming dronespurpose built to be air dropped, U.S. Marine TOW gunner Cpl. Rhet McNeal has developed a hand-launched fixed wing drone, with the help of NexLog (the US Marine Corps’ “Next Generation Logistics innovation group”, in conjunction with Penn State university) and Autodesk.
Autodesk is a CAD design development software company that additionally offers residencies to developers with full access of professional tools and advice at their purpose built Pier 9 workshop in San Francisco, California.
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.
Integrating developments in advanced robotics, big data and 3D printing can help the health sector improve patient care and reduce costs.
The rise of new digital technologies always inspires a wave of excitement and numerous predictions from healthcare experts about revolutionary changes that should be expected. For example, the first real use of 3D printing happened in 1999 and, since then, it has been heralded as a cost-cutting saviour for producing specialist medical equipment. It has even been predicted to be the solution to the challenge of organ transplant shortages. Clearly, the healthcare industry has much to gain from embracing new technology.
Those in the healthcare supply chain acknowledge the importance of new technologies, like advanced robotics, big data and 3D printing, in improving outcomes. In fact, in a recent survey1, 83% of respondents from healthcare and pharma said that big data was the most disruptive technology in the industry today, while 44% named advanced robotics as important to supply chain functions and 35% pointed to 3D printing as a significant disruptor.
Manufacturers are increasingly facing new challenges as they look to stay competitive in the global market place. From changing market forces to the need for increased production efficiency, the issues are broad. And all whilst trying to ensure that the quality of their goods is exceptional and customer response times are kept to a minimum.
It’s clear that manufacturers must innovate in order to tackle these difficulties, and while many are keen to change the way their businesses run for the better, they are also concerned about the mounting pressures around cost and volume of materials used. Today, 3D printing can help tackle some of these challenges, offering transformative advantages at every phase of creation, from initial concept design to production of final products and the steps in between.
Thanks to numerous fantastic test results, you could start think that metal 3D printing has become the most normal thing in the world. Just earlier this month, NavAir successfully tested a MV-22B Osprey fitted with a partially 3D printed engine nacelle, and plenty of similar stories are appearing regularly. You might even be wondering why it took so long. After a decade of innovation, surely we should have progressed passed single 3D printed components? In reality, however, aerospace metal 3D printing has been stuck in a kind of limbo– as nothing more than an interesting new technology that needs more study.
This is perfectly illustrated by the pioneering efforts of Honeywell Aerospace, a global provider of integrated avionics, engines, systems and service solutions for various partners from the aerospace, aviation and defense industries. They were one of the first to begin experimenting with metal 3D printing way back in 2010, but they haven’t gotten much further than a few practical test parts yet. But it seems as though the technology is reaching a turning point, as it is receiving FAA approval and has also become cheaper and faster than competing technologies. As a result, Honeywell has now begun taking the 3D printing technology out of the laboratories, and into the engine development realm. Metal 3D printing is finally ready for lift-off.
Volvo Trucks is a global truck manufacturer based in Gothenburg, Sweden, owned by AB Volvo, and the company is the world’s second largest heavy-duty truck brand. The first Volvo truck was produced in 1928, and by 2011, the firm employed some 19,000 people around the world who manufacture and assemble trucks in 15 countries. The company produces and sells more than 100,000 units every year.
And now Stratasys says Volvo Trucks has decreased turnaround times of critical assembly line manufacturing tools by more than 94% since incorporating additive manufacturing technology into their engine production processes in Lyon, France.