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.
Two new technologies from Stratasys, created in partnership with Boeing, Ford, and Siemens, will bring accurate, repeatable manufacturing of very large thermoplastic end products, and much bigger composite parts, onto the factory floor for industries including automotive and aerospace.
These new 3D-printing technologies and printers include some that are truly boundary-breaking: a sophisticated new sub-$10,000, 10-plus materials bioprinter, the first industrial-strength silicone 3D-printing service, and a clever twist on 3D printing and thermoforming for making high-quality realistic models.
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