The only thing surprising in the Dreamliner delay announced yesterday is that anyone is surprised. As reported here in an award-winning online package, this project is one of the most demanding ever taken in terms of technology and supply chain. The first flight will be delayed six or so months? The Airbus A380 is delayed two years, and it wasn’t a major leap forward. Everything about the Dreamliner is daunting, particularly the brave jump into full-boded composites technology, a move that Boeing bet the whole ranch on. Boeing is sole sourced on the carbon fiber and prepregs that make up the composites. Toray had a fiber capacity of 7,300 metric tons in 2003 and 13,900 metrics tons earlier this year. Huge expansions continue, and Toray’s capacity will approach, if not exceed 20,000 metric tons by 2010, based on Design News estimates. Even more daunting is the effort to automate, and dramatically speed up composite manufacturing processes. As Boeing composites guru Al Miller told me earlier this year: “The technology area still playing out is tooling. Left to its own devices, composite tooling can be fairly elegant or—if you’re not paying attention to it—it can be very clumsy and heavy…We had to meet with our technology partners up front to make sure the technology was mature enough to meet our production schedules.” The builders of the giant tools to make the composite structures are virtually a cottage industry —and one that did not even exist two years ago. The examples go on and on. And what’s more, Boeing, like many other leading edge OEM’s has pushed a huge amount of the development out to its supplier partners. That’s smart, but also risky. I for one applaud Boeing for its efforts, and hope the TV news readers and other headline-focused media don’t shake this tree too hard. In many ways this may be the future of American product development.
Last week, the bill for reforming chemical regulation, the TSCA Modernization Act of 2015, passed the House. If it or a similar bill becomes law, the effects on cost and availability of adhesives and plastics incorporating these substances are not yet clear.
The latest crop of coating and sealant materials and devices has impressive credentials. Many are designed for tough environments with broad operating temperature ranges, and they often cure faster, require fewer process steps, and produce less waste.
A new program has been proposed for testing and certify 3D printing filaments for emissions safety. To engineers who've used 3D printers at home this is a no-brainer. It's from a consumer on Kickstarter, and targets use in homes and schools.
For the last 50 years, the Metal Powder Industries Federation (MPIF) has sponsored an awards competition for creative solutions to designing and fabricating near-net-shape parts using powder metal (PM) technologies. Here are the seven Grand Prize winners of the 2015 contest.
Graphene 3D Lab has added graphene to 3DP PLA filament to strengthen the material and add conductivity to prints made with it. The material can be used to 3D print conductive traces embedded in 3D-printed parts for electronics, as well as capacitive touch sensors.
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