How to Overcome the Additive Manufacturing Challenges in Aerospace

ADDITIVE-MANUFACTURING-MIN
Aerospace manufacturing and design are getting advanced with additive manufacturing. However, the limitations of traditional manufacturing techniques sometimes make it incompetent to produce technologically oriented products. Additive Manufacturing (AM)helps the aircraft system run more efficiently by creating lightweight aircraft parts.

This is one of the reasons that additive manufacturing is gaining traction in aerospace and other industries. According to recent analysis and data, the global additive manufacturing market is expected to grow from USD 9.52 billion in 2020 to USD 27.91 billion in 2028. The expanding technologies and materials used in additive manufacturing will indeed stimulate industry growth shortly.

It’s important to note that there isn’t one channel that is the silver bullet. Most of the time, a combination of different channels will help drive a more powerful outcome.”

– Wendy Lee, Director of Marketing at Blue Prism

However, the aerospace industry encounters some challenges with additive manufacturing, which is the focus of this article. Scalability, multi-material capabilities, professional workers, high-cost materials, and quality compliance norms are all constraints that aerospace professionals are dealing with. Here we will discuss the top three challenges of additive manufacturing in aerospace and their solutions.

Future of Additive Manufacturing in the Aerospace Industry

Even though additive manufacturing has been around for a while, it has only lately become advanced enough to be used in the aerospace sector.
In the aerospace business, additive manufacturing has the potential to deliver significant benefits. Cost savings, design freedom, weight reduction, shorter time to market, fewer waste materials, better efficiency, and on-demand production are just some of the benefits.
Although additive manufacturing cannot make every part, it provides an exciting opportunity to explore feasible alternatives, either supplementing or replacing traditional manufacturing processes. However, it must be taken into account early in the development phase. Additionally, knowledge must be embedded in aircraft design teams to ensure the successful use of additive manufacturing.

However, in recent years, AM has become more prevalent in end-to-end manufacturing. According to Deloitte University Press, the future of AM in aerospace may include:

  • Directly embedding additively produced electronics
  • Wings printing
  • 3D printing engine parts
  • Making battlefield repair components


Top 3 Additive Manufacturing Challenges in the Aerospace Industry and Solutions

While problems are inherent in any new technology, experts overcome them by identifying solutions. Let's look at the top three challenges that the aerospace industry is currently facing and the solutions to overcome them.


Lack of Qualified Experts

Using 3D printers in production and automating work processes are skills that are lacking. However, the obstacles are natural, and the skilled manufacturing workforce is aging and reluctant to adapt to new design models. This is creating the skills gaps surrounding manipulating AM technology.


How to Overcome

Less time spent educating employees is better for business. For example, the US National Additive Manufacturing Institute and the European ADMIRE initiative offer accelerated courses via remote learning websites.
Of course, you'll need to provide numerous additive manufacturing opportunities to attract the key technologists, either on-site or off-site. They will oversee new hires' activities and help them translate their knowledge of 3D printing into designs and final items.


Over Budget Material

The typical cost of AM equipment is $300,000. Industrial consumables cost between $100 and $150 per item (although the final price is formed after choosing the material; plastic, for example, is the most budget-friendly option).


How to Overcome

To overcome this obstacle, you must plan a long-term implementation strategy based on the manufacturing-as-a-service model. On-demand manufacturing reduces manufacturing costs and speeds up product development. You can also go with cheap 3D printers that use cheap welding wire that hasjust come onto the market. They cost $1,200 and may suit your needs.


Fresh Quality Compliance Guidelines

As 3D printing and CNC manufacturing technologies constantly evolve, there are no established norms or regulations for 3D printed objects. However, 3D printed solutions do not always match traditional quality, durability, and strength. For example, a 3D-printed mechanical part. Can someone order 500 similar parts a few months later? Consistency standards and product post-processing may have a negative impact in such circumstances. So, in such a case, traditional manufacturing wins over 3D printing.


How to Overcome

You might endeavor to set quality criteria for your 3D-printed products to ensure they are comparable to traditional ones. You can also apply the ANSI AMSC and America Makes standards, which define quality criteria for 3D printed products.


How Boeing Applies Additive Manufacturing Technology?

Boeing is focusing its efforts on leveraging and speeding up additive manufacturing to transform its manufacturing system and support its growth. The company operates 20 additive manufacturing facilities worldwide and collaborates with vendors to supply 3D-printed components for its commercial, space, and defense platforms.

Boeing is now designing missiles, helicopters, and airplanes using 3D printing technology. A small internal team contributes roughly 1,000 3D-printed components to the company's flight projects. Boeing claims that addressing design as an "integrated mechanical system" considerably improves manufacturability and lowers costs.


Final Words

Additive manufacturing is altering the way the aerospace industry designs and manufactures aircraft parts. Aerospace advanced manufacturing is making aircraft production easier. We've explored solutions to some of the snags that you may encounter. However, other concerns, such as limited multi-material capabilities and size constraints, require solutions, and industry specialists are working on them. Despite these challenges, additive manufacturing is still booming and rocking in a variety of industries.


FAQ


Why is additive manufacturing used in Aerospace?

It allows the industry to build quality parts quickly and inexpensively. Reduce waste and build parts for aircraft that are difficult to manufacture using existing methods.


How does additive manufacturing help in Aerospace applications?

Environmental control system (ECS) ducting, custom cosmetic aircraft interior components, rocket engine components, combustor liners, composite tooling, oil and fuel tanks, and UAV components are examples of typical applications. 3D printing helps in producing solid, complicated pieces with ease.


Which aerospace firms use additive manufacturing/3D printing?

Boeing and Airbus are two of the many aircraft businesses that use additive-created parts in their planes. Boeing incorporates additive manufacturing (AM) components into both commercial and military aircraft. Airbus also employs AM metal braces and bleed pipes on the A320neo and A350 XWB aircraft.

Spotlight

PartsOnDemand

Parts on Demand is the 3D print service of the Vesco Group. With our roots in product development, production and inventing, we are on the frontline of technological development every day. Producing prototypes and small series is part of that and we see an even bigger challenge in optimising production and products.

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Article | December 6, 2021

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Here are the seven additive manufacturing procedures that many manufacturers consider based on their benefits from each process, or whichever approach best suits their product requirements. Material Jetting This additive manufacturing process is quite similar to that of conventional inkjet printers, in which material droplets are selectively placed layer by layer to build a three-dimensional object. After completing a layer, it is cured with UV radiation. VAT Photo Polymerization This procedure employs a technology called photo polymerization, in which radiation-curable resins or photopolymers are utilized to ultraviolet light to generate three-dimensional objects selectively. When these materials are exposed to air, they undergo a chemical reaction and solidify. Stereo lithography, Digital Light Processing, and Continuous Digital Light Processing are the three primary subcategories. Binder Jetting Binder jetting is a process that deposits a binding agent, typically in liquid form, selectively onto powdered material. The print head deposits alternating layers of bonding agent and construction material and a powder spreader to create a three-dimensional object. Material Extrusion S. Scott Crump invented and patented material extrusion in the 1980s using Fused Deposition Modeling (FDM). The continuous thermoplastic filament is fed through a heated nozzle and then deposited layer by layer onto the build platform to produce the object. Powder Bed Fusion Powder bed fusion procedures, particularly selective laser sintering, were the pioneers of industrial additive manufacturing. This approach melts the powdered material and fuses it using a laser or electron beam to form a tangible item. The primary kinds of powder bed fusion are direct metal laser sintering, selective laser sintering, multi-jet fusion, electron beam melting, selective laser melting, and selective heat sintering. Sheet Lamination Sheet lamination is a catch-all term encompassing ultrasonic additive manufacturing, selective deposition lamination, and laminated object manufacturing. All of these technologies stack and laminate sheets of material to form three-dimensional objects. After the object is constructed, the parts' undesirable areas are gradually removed layer by layer. Directed Energy Deposition Directed energy deposition technology employs thermal energy to melt and fuse the materials to form a three-dimensional object. These are pretty similar to welding processes, but are much more intricate. Which Additive Manufacturing Process is best? Why? Based on three fundamental factors, additive manufacturing techniques are categorized into seven types. First, the way material is solidified is determined first by the type of material employed, then by the deposition technique, and finally by how the material is solidified. The end-user often chooses an additive manufacturing technique that best suits his requirements, followed by the explicit material for the process and application, out of the seven basic additive manufacturing processes. Polymer materials are commonly used in AM techniques because they are adaptable to various procedures and can be modified to complicated geometries with high precision. Carbon-based compounds are used to strengthen polymers. Polymers, both solid and liquid, have been widely used due to the variety of shapes, formability, and end-use qualities available. Wherever the light-activated polymer contacts the liquid's surface, it instantly solidifies. Photo polymerization, powder bed fusion, material jetting, and material extrusion are the most common additive manufacturing procedures for polymers. The materials employed in these processes can be liquid, powder, or solid (formed materials such as polymer film or filament). How BASF is Using Additive Manufacturing BASF is a chemical company. BASF, one of the world's major chemical companies, manufactures and provides a range of 3D printing filaments, resins, and powders within its extensive material portfolio. The company, well-known in the 3D printing sector, has formed major material agreements with several 3D printer manufacturers, including HP, BigRep, Essentium, BCN3D, and others. BASF went even further in 2017 by establishing BASF 3D printing Solutions GmbH (B3DPS) as a wholly-owned subsidiary to expand the company's 3D printing business. In addition, BASF stated last year that B3DPS would change its name to Forward AM. BASF's role in the 3D printing business, however, is not limited to material development. BASF has made several investments in 3D printing companies over the years, including the acquisition of Sculpteo, one of the significant French 3D printing service bureaus, last year. BASF sees 3D printing as having a bright future. With the growing popularity of professional 3D printers, all of these systems will eventually require robust, high-quality polymer materials to perform at their best – and BASF has been paving the way to becoming one of the leading solution providers. Final Words All additive manufacturing procedures are unique and helpful in their way. Still, some have additional advantages over others, such as the material used, highresolution, precision, and the ability to build complicated parts. Because of these added benefits, photopolymerization, material jetting, powder bed fusion, and material extrusion are preferred over others. Therefore, choose the AM process that is best suited to your manufacturing business and will assist you in achieving the desired final product output. FAQs What are the benefits of additive manufacturing? AM enables manufacturers to reduce waste, prototyping costs, and customization while conserving energy and increasing production flexibility. Additionally, it benefits the supply chain and the environment, encouraging businesses to increase their manufacturing sustainability. What is the major challenge in additive manufacturing? Many businesses are struggling with the current difficulty of producing large and odd-sized parts using additive manufacturing. So, this can be considered a significant challenge in additive manufacturing. What are the steps of additive manufacturing? The additive manufacturing steps are divided into four steps as below, Step1 - Design a model with CAD software Step2 -Pre-processing Step3 -Printing Step4 - Post-processing { "@context": "https://schema.org", "@type": "FAQPage", "mainEntity": [{ "@type": "Question", "name": "What are the benefits of additive manufacturing?", "acceptedAnswer": { "@type": "Answer", "text": "AM enables manufacturers to reduce waste, prototyping costs, and customization while conserving energy and increasing production flexibility. Additionally, it benefits the supply chain and the environment, encouraging businesses to increase their manufacturing sustainability." } },{ "@type": "Question", "name": "What is the major challenge in additive manufacturing?", "acceptedAnswer": { "@type": "Answer", "text": "Many businesses are struggling with the current difficulty of producing large and odd-sized parts using additive manufacturing. 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Kardex has agreed a strategic partnership with Addverb in the area of intralogistics software. Addverb is a leading global robotics and warehouse automation company based in India. The cooperation combines Kardex's expertise in the area of compact storage systems with Addverb's outstanding warehouse management technology. Addverb's highly innovative warehouse management system is based on a modern microservices architecture and fully operable in the cloud. The partnership between Kardex and Addverb enables an integrated and efficient solution package with the latest technologies in the area of warehouse management and automation. The overall package of Addverb software and Kardex storage systems offers seamlessly integrated and optimized storage processes for companies of all sizes in all industries. Addverb's warehouse management solution is based on a microservices architecture that makes it seamlessly scalable and extremely flexible. In addition to which it features a user-friendly interface that eases the implementation and administration. With its algorithms optimizing the handling of resources and materials, the Addverb system ensures optimized workflows and greater productivity. The cloud-based architecture meanwhile guarantees global access and real-time data for optimal decision-making with the highest possible security standards. The partnership between Kardex and Addverb is an important step forward in the advancement and innovation of warehouse management technologies. Both companies are convinced that their joint effort will contribute to boosting the efficiency and agility of companies worldwide. "Thanks to the partnership with Addverb, we are able to offer our clients one of the most advanced warehouse management solutions for highly efficient storage. The combination of our technologies will set new standards in the integration of logistics systems" emphasizes Dr. Volker Jungbluth, Head of Corporate Technology at Kardex. The strategic partnership enables extensive synergies between the two companies. "Together with Kardex, we will be able to offer our clients first-class solutions that will revolutionize their warehousing processes and make them more competitive", says Pieter Feenstra, CEO Addverb EMEA.

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Additive Manufacturing

Teledyne Relays Unveils Innovative Multi-Function Timer Series

Teledyne Relays, Inc. | January 29, 2024

Teledyne Relays, a leading provider of cutting-edge relay solutions, introduces its new Multi-Function Timer product series, showcasing the company's commitment to delivering advanced, reliable, and versatile solutions for the industrial automation sector. Teledyne Relays Multi-Function Timer MFT series is a state-of-the-art solution designed for a wide variety of applications that demand precise timing control. The user-friendly design features three potentiometers for easy selection of timing functions and ranges, while the LEDs provide at-a-glance feedback of timing and relay status. The MFT series also features 7 selectable timing functions for a wide variety of applications Timing ranges from 0.1 seconds up to 100 hours Compact 17.5mm housing preserves valuable panel space Supply Voltages: 24VDC & 24-240VAC OR 12-240VAC/DC 5A SPDT output relay Engineered with the needs of electrical engineers, panel builders, and automation engineers in mind, these timers find application in various industries, including but not limited to Industrial Automation Manufacturing Process Control Systems HVAC and Refrigeration Agriculture and Irrigation Power Distribution “With the new Multi-Function Timer series, Teledyne Relays continues to lead in providing reliable and versatile solutions for industrial automation, ensuring precise timing control,” said Michael Palakian, Vice President of Global Sales and Marketing at Teledyne Relays. The Multi-Function Timer series from Teledyne Relays ensures precise timing control, offering unparalleled reliability across diverse applications and is available for ordering from Teledyne Relays or an authorized distributor. About Teledyne Relays Teledyne Relays is a world leader in high-performance coaxial switches, electromechanical, and solid-state relays, offering a wide range of solutions for various applications in the aerospace and defense, telecommunications, test and measurement, and industrial markets. With over 60 years of experience, Teledyne Relay has established a reputation for quality, reliability, and customer service excellence. About Teledyne Defense Electronics Serving Defense, Space and Commercial sectors worldwide, Teledyne Defense Electronics offers a comprehensive portfolio of highly engineered solutions that meet your most demanding requirements in the harshest environments. Manufacturing both custom and off-the-shelf product offerings, our diverse product lines meet emerging needs for key applications for avionics, energetics, electronic warfare, missiles, radar, satcom, space and test and measurement.

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Manufacturing Technology

Detroit Manufacturing Systems Strikes Partnership with InductEV to Accelerate Adoption of High-Power Wireless Charging for Commercial Vehicles

Detroit Manufacturing Systems (DMS) | January 11, 2024

Wireless commercial vehicle charging took a big step forward with an agreement between Detroit Manufacturing Systems and InductEV. In the landmark agreement, DMS, a large-scale, U.S.-based assembly provider, will bring its operations, manufacturing, quality by design, and supply chain expertise to InductEV allowing the latter to more quickly scale to meet customer demand. InductEV is reinventing how electric commercial fleet vehicles charge their batteries by charging on route, using clean renewable electricity. With its wireless induction solution now deployed worldwide and with 18 patents granted and 23 in process, the King of Prussia, PA-based company is the global leader in high-power, high-speed wireless EV charging and AI-software powered energy management. Under the terms of this agreement, DMS will Manufacture InductEV's hardware, including in-ground and under-vehicle inductive pads. Manage InductEV's supply chain and procurement. Utilize engineering expertise to facilitate high quality, design for manufacturing and assembly. Co-develop design optimizations to prepare for a 100-fold increase in production volume. "We couldn't be more pleased to have a manufacturing partner, known for its high standards and operating rigor, combine forces with our proprietary engineering," said Barry Libert, Chairman and CEO, InductEV. "Our complementary areas of expertise will enable us to meet the growing demand from commercial fleet owners and operators, as well as Intermodal facilities and Ports, for our advanced, AI-managed wireless charging solution." Among its product offerings, Detroit Manufacturing Systems currently handles manufacturing for the Ford EV F-150 Lightning signaling its expertise in advanced electric vehicle components and systems production. InductEV's patented technology is currently being used in locations throughout North America and Europe, including in Washington State, Indianapolis, Martha's Vineyard, and in Gothenburg, Sweden, Volvo's hometown. (Volvo Ventures is an InductEV investor.) The company is poised to announce the largest commitment by a U.S. port facility to its wireless charging technology. "We recognize and applaud InductEV's efforts to wirelessly electrify commercial fleets, the biggest contributor in transportation to greenhouse gas emissions worldwide," added Bruce Smith, Chairman and CEO, Detroit Manufacturing Systems. "We look forward to bringing our manufacturing, quality and supply chain expertise to this partnership and creating a successful venture that will help reduce this sector's carbon footprint at a considerable cost savings for all involved." InductEV's proprietary, on-route wireless charging solution shifts EV charging to daytime use of renewables. It reduces the need for large EV batteries, lowering vehicle costs, and eliminates the need for recycling by extending battery life by a factor of 4-8X. Wireless charging also enables the broad deployment of autonomous vehicles. About InductEV InductEV is revolutionizing how electric commercial fleet vehicles charge their batteries. With its proprietary on-route wireless solution now deployed throughout North America and Europe and with 18 U.S. patents and 23 pending, the King of Prussia, PA-based company is the global leader in high-power, high-speed wireless EV charging and AI-software powered energy management. The company just opened one of world's first R&D centers for wireless vehicle charging. About Detroit Manufacturing Systems (DMS) Detroit Manufacturing Systems (DMS) is a contract manufacturing and assembly company that is committed to and is constantly striving for manufacturing excellence and perfect quality. This is achieved through meticulous mistake proofing and a culture of continuous improvement. DMS' GIFTED & RICH fundamental beliefs, management principles, and core values guide the staff in proactively and transparently engaging with customers and suppliers. DMS is also committed to protecting the local and global environment and minimizing the environmental impacts concerning their activities, products and services.

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