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Biggest, Fastest Titanium 3D Printer
10/8/2012

Airbus, aerostructure manufacturer Aerosud, and the South African Council for Scientific and Industrial Research, are partnering to develop the biggest, fastest 3D printer possible for making titanium aircraft and satellite components. Shown here, the Airbus A380 demonstrator aircraft arrives at the 2012 Farnborough International Airport.   (Source: Airbus)
Airbus, aerostructure manufacturer Aerosud, and the South African Council for Scientific and Industrial Research, are partnering to develop the biggest, fastest 3D printer possible for making titanium aircraft and satellite components. Shown here, the Airbus A380 demonstrator aircraft arrives at the 2012 Farnborough International Airport.
(Source: Airbus)

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naperlou
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Strength
naperlou   10/8/2012 10:48:16 AM
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Ann, this is interesting news.  One question I would have is on the strength of the materials.  In general, machined materials are stronger than injection molded materials.  Of course, if the strength is enough for the purpose, then that is enough.  Then the speed of manufactur is all important.

Ann R. Thryft
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Re: Strength
Ann R. Thryft   10/8/2012 12:35:30 PM
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Lou, the strength of the PM/sintered titanium powder metal parts produced by Dynamet has received approval from Boeing for use in structural aircraft parts, after a few years of testing. That news is pretty amazing on its own. The fact that Airbus has signed on to the Aeroswift aircraft structures project to help test selective laser-sintered titanium parts is another vote of confidence. It will be interesting to see what happens during that test phase.



Charles Murray
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Re: Strength
Charles Murray   10/8/2012 6:33:13 PM
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Ann, do we know how big the printer is, or how big the parts can be?

Ann R. Thryft
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Re: Strength
Ann R. Thryft   10/9/2012 12:35:16 PM
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Chuck, I looked all over for build volume and printer size with no luck. The only clue is that it's designed to build components of large aircraft structures. I'm guessing several feet per side of build volume. Very large 3D printers exist in architectural apps for use with sand and soil and their build volumes can be 2m x 2m x 5m up to 6m x 6m x 2m, and even larger in the works.

JimT@Future-Product-Innovations
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Strength and Size
JimT@Future-Product-Innovations   10/9/2012 1:00:17 PM
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Ann - thanks for offering the large size baths that are still being developed.  I had no idea that 3D makers were developing apparatus that large. 6 meters square-?  That's enormous. That's about 50 feet across diagonal; large enough to make a wingspan frame.  Wow.

Ann R. Thryft
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Re: Strength and Size
Ann R. Thryft   10/9/2012 2:05:33 PM
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Jim, note that those huge build volumes are for building architecture apps, not for aircraft. We don't know the build volume of the Aeroswift machine.

JimT@Future-Product-Innovations
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Re: Strength and Size
JimT@Future-Product-Innovations   10/9/2012 6:38:18 PM
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OK, noted;  do you know an example of the architectural Apps -?  I'm fuzzy on that, and wondering if it's a stretch between architectural and aeronautical ,,, ?

Ann R. Thryft
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Re: Strength and Size
Ann R. Thryft   10/10/2012 12:09:20 PM
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Jim, the architectural apps are for buildings. If you google "3D printed buildings" you'll find several different versions. Unless you want to make airplanes out of sand and cement, there's no relationship in products. But figuring out to make larger build volumes is, to some extent, a generic 3D printing problem, which is why I mentioned the larger build volumes of the architectural apps.

JimT@Future-Product-Innovations
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Re: Strength and Size
JimT@Future-Product-Innovations   10/11/2012 1:11:57 PM
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Ann- thanks- I did search per your advice, and found this:

http://www.popsci.com/technology/article/2012-08/researcher-aims-print-3-d-print-entire-houses-out-concrete-20-hours

,,,which opens a whole new paradigm for me. Very thought provoking and encouraging for new innovative methods for everyday things. (Too bad the associated comments under this linked story are so negative and narrow minded - it helps remind me that even break-thru progress has anchors to drag.)

Ann R. Thryft
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Re: Strength and Size
Ann R. Thryft   10/11/2012 1:36:00 PM
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Jim, so glad to give you info about something new that sparks your creative thinking. I think the potential of 3D printing technology can be applied in all kinds of ways we haven't thought about yet. I really enjoy doing that here at Design News. I don't expect everyone to agree or find what I write about interesting. But I'm glad that many enjoy the new and different technologies I find. Creativity has sometimes been defined as bringing together disparate elements in a new way.

Dave Palmer
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Re: Strength
Dave Palmer   10/8/2012 1:06:21 PM
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@naperlou: Selective laser sintering typically doesn't yield a fully-dense part, so the mechanical properties would be significantly inferior to those of a forging.  On the other hand, it has been shown that selective laser sintering followed by hot isostatic pressing can give mechanical properties equivalent to conventionally-processed titanium.

It seems like a good move for South Africa to go from an exporter of raw materials to a manufacturer of high-tech components.  Other developing countries could benefit from this example.

Cadman-LT
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Great article
Cadman-LT   10/8/2012 1:04:26 PM
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Great article Ann. I always like learning about the new things they are doing with 3D printing. Titanium now, what's next? Keep the articles coming!

Greg M. Jung
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Economics
Greg M. Jung   10/11/2012 9:08:35 PM
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I am also impressed with the forward thinking ability of this South African consortium to strategically invest in processes that produce net shape titanium rather than raw titanium, thus capitalizing on much higher profit margins.  This vertical business integration will help both their organizations and their country.

Ann R. Thryft
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Re: Economics
Ann R. Thryft   10/12/2012 12:00:55 PM
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Greg, I agree, and I thought Dave's comments were also to the point regarding vertical integration in South Africa all the way from raw materials to exported products. Looks like a very wise business move for the country overall.

bobjengr
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3D PRINTING
bobjengr   11/23/2012 5:23:32 PM
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Excellent article Ann.  I have followed "additive manufacturing" over the past few years and remain fascinated by the possibilities.   Right now it appears the various types are as follows:

·         (SLA) Stereolithography

·         (SLS) Selective Laser Sintering

·         (FDM) Fused Deposition Modeling

·         (3DP) Three Dimensional Printing

·         (Pjet) Poly-Jet

·         Laminated Object Manufacturing

Stereolithography, of course, was the very first.  There are two things that really amaze me about the processes: 1.)  The size of manufactured product grows each year and 2.) The materials used for the each method expand and grow each year.   I would not be surprised at all is the testing planned yield components that "make the grade" as far as specifications.  I suspect they could exceed expectations.  Again, great post.

  

 

Ann R. Thryft
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Re: 3D PRINTING
Ann R. Thryft   11/28/2012 11:28:22 AM
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bobjengr, the number of AM techniques is actually pretty small. Basically, there's SLA, (S)LS, and FDM. Various forms of "3D printing" ("3DP" is a term invented by MIT), are simply doing AM with an inkjet-type nozzle that sprays material in all three directions (X, Y, Z) for creating layers. PolyJet, for instance, is not a separate method, but an SLA technique using inkjet methods. A caveat: the term "3D printing" is now used, confusingly, to refer to all types of additive manufacturing. You also listed Laminated Object Manufacturing, which (obviously) uses lamination. This is a rapid prototyping method that competes with SLA and SLS, but is not considered an AM technique.
One of the best AM resources I've found is here:
http://www.wohlersassociates.com

vkalanov
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Iron
Re: 3D PRINTING
vkalanov   1/8/2013 11:41:59 AM
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My company Control Systems Technologies, LLC holds four patents in modular robotic technology.  We basically form a multi degree of freedom configuration (synchronous 6 DOF) around an application and thus shape a work space according to a customer's need.  Our path planning program is based on an API that is directly tied to SolidWorks thus enabling the user to form a 3D path within minutes (including cladding paths) to be executed on an existing part and/or slicing if the part needs to be built.  I think that this technology can be applied readily in 3D printing applications.  Please let me know who I may contact in order to see if there is a fit.

Many thanks,

Dr. Kalanovic, Owner

Vojislav.Kalanovic@sdsmt.edu

www.consytec.org

 

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