Booming demand for aircraft and power generation plants is fueling higher requirements for a specialized investment casting process that creates complex hollow internal shapes. Use of molded ceramic cores allows turbine engine blades and vanes to be cast to size with complex cooling passages, permitting engines to operate at higher temperatures with greater efficiency. GE Aviation has a record number of engines on order through 2012, its third record year in a row. The cores are also used for turbines in natural gas power generation plants.
One of the beneficiaries is a company called Certech, which is the largest independent producer of ceramic cores for investment casting. Technology growth is in materials development. “We’re always looking for a better mousetrap to give a better yield to the customer,” says Michael Kasberg, vice president and general manager of Certech. “When they pour metal around our parts sometimes they want to pour hotter metal. As a result you need a ceramic that won’t melt when it sees a higher temperature. “
BMW has already incorporated more than 10,000 3D-printed parts in the Rolls-Royce Phantom and intends to expand the use of 3D printing in its cars even more in the future. Meanwhile, Daimler has started using additive manufacturing for producing spare parts in Mercedes-Benz Trucks.
SABIC's lightweighting polycarbonate glazing materials have appeared for the first time in a production car: the rear quarter window of Toyota's special edition 86 GRMN sports car, where they're saving 50% of its weight compared to conventional glass.
Design engineers play a big role in selecting both suppliers and materials for their designs. Our most recent Design News Materials Survey says they continue to be highly involved, in some ways even more than the last time we asked to peek inside their cubicles.
Daihatsu is one of the first carmakers to customize car exteriors using 3D printing's mass customization capabilities. Effect Skins -- small exterior bumper and fender panels in different colors and textures -- can be ordered for its Copen convertible.
Several new products in this group of new adhesives, coatings, and sealants are formulated to protect sensitive electronic components, or to seal components of commercial and military aircraft. Others are designed to operate in tough, messy, dirty oil & gas operations, or for rotary applications and motors.
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