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.
Several of the new and noteworthy 3D printers in this slideshow are breaking some boundaries in build volume, new metals printing techniques, or working with high-profile development partners to ensure very high-quality parts and controls.
United Launch Alliance will fly 3D-printed flight hardeware parts on its rockets starting next year with the Atlas V. The company's Vulcan next-gen launch vehicle will have more than 100 production parts made with 3D printing. The main driver? Parts consolidation and 57% lower production costs.
A new report from the National Institute of Standards and Technology (NIST) makes a start on developing control schemes, process measurements, and modeling and simulation methods for powder bed fusion additive manufacturing.
Although bio-based polymers face challenges from petroleum-based polymers, in certain markets they can displace the petro-based incumbents. Here are six new bio-based and renewable plastics for a variety of applications.
BASF has developed tools and initiatives to help engineers use more of its renewable materials in their designs, more effectively, as well as to build parts using them with more predictable performance.
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