Look for intense collaborative research efforts over the next 10 years to improve additive manufacturing technologies for use in high-tech aerospace applications. The cost of aerospace components is boosted dramatically due to the amount of material beyond the finished geometry that must be removed during manufacturing-often 90 percent or more, according to Chris English, an engineer with GE Aviation. As a result there is increased interest in the potential to use additive manufacturing technologies that were originally developed for rapid prototyping applications.
One example is a project at the George W. Woodruff School of Mechanical Engineering at the Georgia Institute of Technology. Researchers there are looking at the potential to produce net shape low-density cellular metal structures from layer-based additive manufacturing of metal-oxide ceramic slurry followed by post-processing in a reducing atmosphere. A ceramic suspension would be direct printed in a research investigation. Many issues remain, however, with existing additive manufacturing systems including materials available, poor surface finish, difficulties in removing support systems, and inability to make large parts.
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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