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.
NASA and Boeing developed a huge, carbon composite cryogenic fuel tank for deep space missions, and started testing it last month. The 18-ft cryotank will enable heavy-lift launch vehicles to send both humans and robots into deep space.
German engineering firm EDAG Group showed a single-piece, 3D-printed car body design inspired by a turtle at the Geneva Motor Show. It came about after an assessment of how additive manufacturing could be applied to making industrial components, modules, and complete vehicle bodies.
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