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Additive Manufacturing in the Aerospace Industry

Arpita Halder | June 02, 2022 | 712 views
ADDITIVE_MANUFACTURING_IN
Over the last few years, additive manufacturing (also known as 3D printing) has garnered much attention and appreciation, both from consumers and the manufacturing fraternity. 3D printing, which started as a prototyping technology, has come a long way since its inception. To put it in simple words, additive manufacturing (AM) is a game-changer for manufacturers of all sizes.

Traditional ways of generating products such as machining, cutting, turning, shaping, milling, and other "subtractive" manufacturing processes can be supplemented, and in some circumstances, completely replaced, by additive manufacturing. When we look at the bigger picture, AM is transforming people’s lives, which includes but is not restricted to just medical advances, safer transportation, highways, or any other infrastructural developments.

Manufacturers can now swiftly make mock-ups of a new product or a part to fulfill a specific market niche, which can lead to the production of high-profit margin products. When additive manufacturing is used from start to finish, the overall manufacturing process becomes even more streamlined.

Given the advantages of AM, it's only natural that the technology would be used in the aerospace industry. According to MarketanndMarkets, aerospace 3D printing is expected to exceed $3 billion by 2022 due to the rising demand for lightweight 3D printed parts for aircraft engines.

Here are some areas where AM is implemented in the aerospace industry.


Constructing Rocket Bodies:

Relativity Space is a California-based aerospace manufacturing firm that focuses on creating manufacturing technologies, launch vehicles, and rocket engines for commercial orbital launch services. Their Stargate manufacturing facility is known to house the world's largest 3D printers. These printers use direct energy deposition and patented alloys to make the outer bodies of their rockets.

When compared to traditional launch vehicles, 3D printing allows them to quickly create integrated components with a 100-fold lower part count. This also reduces weight and increases reliability, both of which are critical to the economics of space launch. It further allows designers to explore numerous designs in a short time span and helps enhance the overall quality and arrive at a better design.


Designing Rocket Engines:

Rocket Lab is a public American aerospace company that specializes in small satellite launches. Their Rutherford rocket engine was first tested in late 2016, and over 200 of these game-changing variants have been manufactured since then.

The combustion chambers, injectors, pumps, and main propellant valves of this engine were all 3D printed utilizing electron-beam melting. The resulting engine is simple, dependable, and light, weighing only 35 kg (77 lb), making it perfect for low-cost space launches. Their new Curie and HyperCurie thrusters, which operate outside Earth's atmosphere, are based on the same principles.


Designing Astronaut Outfits:

Additive manufacturing isn't just for making actual rockets; it may also be used to create improved, refined astronaut outfits. The costumes of SpaceX's crew were partially produced with additive manufacturing when they sent humans into space.

Even though the company has kept much of the underlying technology under wraps, a source shared that the helmet was made by using 3D printing technology and it had integrated valves, visor retraction and locking mechanisms, and microphones built into the structure.


Wrapping Up:

The current pace of manufacturing and engineering really necessitates the need for everyone to invest in additive manufacturing.” 

Cory Larson WMEP Manufacturing Solutions Consultant – Automation & Cybersecurity, Registered Practitioner, CMMC-AB

AM is also gaining traction in the commercial manufacturing and fabrication markets. Metal fabrication companies all around the world have begun to provide additive manufacturing solutions in addition to subtractive methods like CNC machining. 3D printing is swiftly becoming one of the cornerstones of the industry 4.0 movement due to its capacity to generate high-tolerance parts and rapid prototypes at a substantially reduced cost.

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