Additive Manufacturing In Aerospace
3 D P r i n t i n g Ta ke s F l i g h tAdditive Manufacturing in Aerospace
AgendaIntroductionTechnology OverviewUnique Benefits of 3DPApplicationsToolingEnd Use PartsWhat’s Next?
3DP Market OutlookGrowing market: hardware salesestimated to reach 6.6B in 2017,up from 2.2B in 201285% of that figure will be fromindustrial machinesDriving Markets: AerospaceDefenseAutomotiveCopyright Taylor-Deal Aviation
3DP AdoptionSmall and large firmsare adopting additivemanufacturingUses range fromprototyping to end useparts
Whose Playing in A&D?
A&D Applicability
Aerospace DriversIterative and adaptive designImproved design validationLow cost, on-demand toolingIncreased part complexity, reduced weightDistributed Manufacturing
Adaptive DesignAdditive manufacturing allows for designadaptability, mass customization, andreconfigurability
Adaptive Design“Free” design changes Cost of iteration reducedChanges to production parts with less impact
Design ValidationPrototypes for physicaland/or destructivetesting can supplementFEA and CFD analysis
Design ValidationFit & assembly prototypesavailable faster and cheaper
Rapid ToolingTooling applications often overlooked points of ROIJigs/fixturesCasting patterns (investment, sand, urethane)Thermoforming patternsComposite tooling (positive molds, clam shell, solublecore)Sheet metal forming toolsInjection molding tools
Part Complexity3DP simplifies BOM by combining partsParts are optimized for “needs” rather than“creation”
Weight ReductionIncreased design freedom leads to reduced weight ofend use partsFuel savings – 20lbs can save up to 500,000/yearRepurposing of weight reserveNon-structural parts such as interiors, air ducting,cargo brackets, and passenger compartmentcomponents are being printed now. Structuralcomponents to follow.
Weight ReductionGE Design Challenge – jet engine loading bracket Original bracket: 4.48lbChallenge winner: 0.72lb (84% weight savings)
Distributed ManufacturingShift in supply chain from traditional modelManufactured - Inventoried - Distributed from different locations3DP enables parts to be created on location
Technology OverviewPrimary technologies used in A&D:FDM (Fused Deposition Modeling)DMLS (Direct Metal Laser Sintering)EBM (Electron Beam Melting)These technologies stand out for their highperformance materials
FDM OverviewInvented in the mid-1980s by StratasysPrints in real thermoplastic materialsABSPolycarbonateNylonESD-7PPSFUltem 9085Parts are functional, durable, andindustry-readyOffice friendly technology
FDM Overview
FDM OverviewModel.005, .007, .010, .013 SliceSupport.020X-AxisZ Axis
FDM - Timelapse
FDM – Ultem MaterialUltem 9085 is a hightemperature, highperformancethermoplasticFAA compliant forsmoke, flame, toxicityParts can be 8130certified
DMLS3D printing from powder metalsLaser “sinters” patterns into powder, binding the layers0.0006” slice heightMultiple material options:Stainless steelsHot-work steelsTitaniumGold
Concept Laser LaserCUSING hybrid insertsHybrid-base onmeasuring machineHybrid base inLaserCUSING machineFill up withmetal powderLaserCUSING processFinish LaserCUSING HardeningCNC millingInsert is ready
DMLS
EBMPowder-based metal printingtechnologyHigh power electron beam firesin a vacuum chamber, meltinglayers of pure metal alloyEBM known for creating dense,void-free partsFaster than other metal printingtechnologies
EBM
Aerospace & Defense ApplicationsA&D companies are using additive manufacturingincreasingly for tooling and end-use parts
ThermoformingForming tools for creating thin,plastic parts.FDM tools can be built withinternal structureDesigned with internal porosityand stiffness in mindIdeal for complex shapesPerform as-well or better thantraditional toolingCommon uses include interiorand passenger compartmentparts¼” Kydex (acrylic/PVC alloy)
Composite T
Forming tools for creating thin, plastic parts. FDM tools can be built with internal structure Designed with internal porosity and stiffness in mind Ideal for complex shapes Perform as-well or better than traditional tooling Common uses include interior and passenger compart
Aerospace Markets Shawn Kelly, Ph.D. Senior Engineer, Additive Manufacturing and Lasers Director, Additive Manufacturing Consortium skelly@ewi.org , 614.688.5145 1 Ian D. Harris, Ph.D. Technology Leader, Arc Welding Founding Director, Additive Manufacturing Consortium iharris@ewi.org , 614.688.5131
INSIGHT08 - Additive Manufacturing - Applications in Aerospace - September 2018 The benefits of Additive manufacturing Additive manufacturing can provide several benefits to the end user - these are shown in Figure 5. It is worth noting that all six benefits identified below ultimately lead to a reduction in processing costs to the end user.
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Additive manufacturing (AM) is the process of building objects by creating successive layers of a material. It includes the processes of 3D printing, rapid prototyping, freeform fabrication, and more. Additive manufacturing creates objects by adding material layer-by-layer until completion. Think of how a house of bricks is built—additive .
Additive Manufacturing Standards Development Structure. ISO and ASTM International published the jointly crafted Additive Manufacturing Standards Development Structure, a framework to help meet the needs for new technical standards in this fast-growing field. The structure was approved by the organizations' additive groups in July 2016.
or advanced manufacturing methods, such as additive manufacturing, cryogenic machining, and Powder metallurgy-HIP) Are you considering using nontraditional or advanced methods of manufacturing (e.g., additive manufacturing (AM, 3-D printing), powder metallurgy-hot isostatic pressing, electron beam welding, etc.)
simulation, and manufacturing into your Inventor workflows. Assess the business case of using metal additive manufacturing to manufacture your products. Discover how Autodesk Fusion 360 can enable you to solve complex design and manufacturing challenges. Compare several metal additive manufacturing technologies and the advantages
Data-driven modeling of thermal history in additive manufacturing Mriganka Roy 1 and Olga Wodo†2 1Department of Mechanical and Aerospace Engineering 2Department of Material Design and Innovation May 20, 2019 Abstract Additive manufacturing (AM) has the potential to construct complex geometries through the
