Additive manufacturing the next big thing?

November 30, 2015

Additive manufacturing is a process of making components layer by layer from powered materials. Initially, the technology was used to produce prototype parts, but now it is being used to build in-flight production components for aircrafts.

For functional aircraft components, aerospace manufacturers are increasingly using 3D printing techniques. Rolls-Royce Trent XWB-97 engine that powers A380 aircraft will be equipped with the largest aero engine component built using 3D-printing technology. The component has 48 aerofoil shaped parts and a front-bearing housing , which measures 1.5m, each of which was produced by 3D printing.

GE is also planning to print fuel nozzles for the LEAP engine that is being developed in partnership with Snecma. Such 3D-printed nozzles will be 25% lighter and five times more durable than existing nozzles. 50m $ facility in Alabama seems to be the first plant in the world to go for mass production of 3D-printed aero-engine components.

GKN Aerospace, Boeing and many other companies are also actively investing in additive manufacturing. 3D printing offers great potential to reduce cost and enables the design and production of monolithic structures more efficient.

Existing 3D-printed components are made from titanium 6Al-4V powder and the next stage is tweaking those alloys for other production processes to make them more receptive to electron beam melting. Particularly for aero-structure components, additive manufacturing is a process of making those parts from a near-net [shape] that saves cost, because you are not throwing wastage material away.

Source:http://www.theengineer.co.uk/aerospace/in-depth/aerospace-takes-to-additive-manufacturing/1021249.article