How to Overcome the Additive Manufacturing Challenges in Aerospace

Bhagyashri Kambale | December 06, 2021 | 950 views
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

Industrial Automation Group

Unlike many integrators who claim to be experts in every industry segment, Automation Group knows who we are. We serve the Food and Beverage industry and we serve it well. Our specific product and application experience has lead us to the implementation of complex automation solutions across North America.

OTHER ARTICLES

Achieving Interoperability in an Industry 4.0 Factory

Article | February 11, 2020

As a part of the Industry 4.0 movement, factory engineers are increasingly adopting some form of industrial Ethernet to interconnect the machines and other equipment implementing their production processes. Ethernet has been around in multiple forms for over 40 years. Most of it serves the IT community by interconnecting PCs and other equipment to a company LAN. Because of its flexibility, Ethernet has been adapted to many industrial uses.

Read More

The Impact of Coronavirus on Electronic Manufacturing

Article | February 11, 2020

Wuhan, the epicenter of the outbreak, is considered a crucial hub in the middle of China, a place of high importance for the production of automobiles, electronics, optics, and fiber optics. Wuhan and surrounding cities in the Hubei province are currently on a government-imposed quarantine at a scale the world has never seen before, some Chinese officials have referred to the situation as warlike.

Read More

Digitalizing Your Manufacturing Ecosystem

Article | February 10, 2020

Making digitalization work for you requires an understanding of your manufacturing ecosystem. Standards - such as ISA-95 - only guide you on a journey to more deeply comprehend the workings of your unique process for manufacturing your products. A batch manufacturing ecosystem often includes campaign management. Campaign management is not mentioned in ISA-95, which only speaks generally of order processing.

Read More

4 Food and Beverage Manufacturing Trends on Tap for 2020

Article | February 10, 2020

It’s the food and beverage industry’s job to appeal to consumer tastes by keeping tabs on what’s hot and what’s not. In the 1990s, for instance, fat free or reduced fat was all the rage, evidenced by the variety of products with such descriptions featured in bold typeface on cartons, cardboard and boxes. Fast forward to today, thanks in part to advancements in nutrition science, fat is back and is recommended in low-carb diets such as Atkins and Keto.

Read More

Spotlight

Industrial Automation Group

Unlike many integrators who claim to be experts in every industry segment, Automation Group knows who we are. We serve the Food and Beverage industry and we serve it well. Our specific product and application experience has lead us to the implementation of complex automation solutions across North America.

Related News

MANUFACTURING TECHNOLOGY

NUBURU and GE Additive Sign Joint Development Agreement

Businesswire | June 02, 2023

NUBURU, Inc., a leading innovator in high-power and high-brightness industrial blue laser technology, today announced that it has signed a joint technology agreement with GE Additive, to explore the speed, accuracy, and commercial benefits of blue laser-based metal 3D printing. “As we continue to advance our proprietary blue laser technology, we have further increased both power and brightness to open up new applications,” said Dr. Mark Zediker, CEO and co-founder of NUBURU. “We’ve achieved key performance milestones that open new possibilities for significant advances in metal 3D printing. Working with GE Additive, and their expertise in metal additive manufacturing, will allow us to rapidly optimize our innovative area printing approach. That will accelerate the further expansion of our pioneering blue laser into innovative metal 3D printing solutions which have the potential to change the landscape of military logistics; aerospace manufacturing; medical device fabrication, and beyond.” “As an industry leader in metal 3D printing and having been on the leading edge of qualifying parts in regulated industries, we’re excited to evaluate NUBURU blue industrial laser technology and its benefits,” said Chris Schuppe, General Manager, Engineering & Technology of GE Additive. NUBURU’s novel approach to additive manufacturing is built on the foundation of blue light absorption by metals, a fundamental physical advantage that offers the highest efficiency laser-based melting for a wide range of industrially important metals. Combining the blue laser module with an innovative optical conditioning system, the NUBURU light engine is at the heart of the expected performance improvements. GE Additive will provide a powder bed system and expertise in the integration and characterization of this next generation prototype light engine, to quantify the performance improvements over existing technology. This joint development agreement is in addition to an agreement with GE Additive to support NUBURU’s previously announced AFWERX Small Business Innovation Research (SBIR) Phase II contract awarded to NUBURU in 2022. About NUBURU Founded in 2015, NUBURU, INC. (NYSE American: BURU) is a developer and manufacturer of industrial blue lasers that leverage fundamental physics and their high-brightness, high-power design to produce faster, higher quality welds and parts than current lasers can provide in laser welding and additive manufacturing of copper, gold, aluminum and other industrially important metals. NUBURU’s industrial blue lasers produce minimal to defect-free welds that are up to eight times faster than the traditional approaches — all with the flexibility inherent to laser processing. For more information, please visit www.nuburu.net. About GE Additive GE Additive – part of GE (NYSE: GE) is a world leader in metal additive design and manufacturing, a pioneering process that has the power and potential to transform businesses. Through our integrated offering of additive experts, advanced machines, and quality powders, we empower our customers to build innovative new products. Products that solve manufacturing challenges, improve business outcomes, and help change the world for the better. GE Additive offers Direct Metal Laser Melting, Electron Beam Melting and Binder Jet metal additive technologies, as well as AddWorks™ consulting services, software and metal powders. www.ge.com/additive.

Read More

FUTURE OF MANUFACTURING

Coherent Introduces New Laser Welding Head With Tactile Seam-Tracking Technology for Electric Vehicle Manufacturing

Globenewswire | June 01, 2023

Coherent Corp., a leader in advanced laser processing solutions, today introduced HIGHtactile, a new laser welding head with tactile seam-tracking technology ideal for electric vehicle (EV) manufacturing applications. The growing demand for EVs is expanding applications for lasers in automotive manufacturing, spurring innovations in process automation and improvements in laser usability. Coherent introduced HIGHtactile, a laser processing head with a new patent-pending seam-tracking technology that is easily configurable to perform highly automated fillet welding and brazing. “HIGHtactile is the culmination of twenty years of experience designing seam-tracking systems for welding and brazing, making it a truly unique product on the market,” said Dr. Karlheinz Gulden, Senior Vice President, Laser Components and Subsystems Business Unit. “Our laser processing heads have had great success in automotive manufacturing applications. Now, with the rapidly growing demand for electric vehicles, we are addressing a broad range of new opportunities in critical applications, such as fillet welds that enable battery trays to be stronger and stiffer while at the same time reducing weight.” HIGHtactile is extremely user-friendly, thanks to its wide range of embedded sensors that streamline almost every functional aspect of the welding head. The sensors improve process learning and enable faster laser processing. HIGHtactile can be configured to maximize performance for specific applications such as brazing steel or welding aluminum and steel. Those processes are typically found in body-in-white applications such as trunk lid and roof top brazing. HIGHtactile can be used with a wide range of lasers, wire feeders, and process monitoring systems. Coherent will exhibit at Laser World of Photonics, in Munich, Germany, June 27-30, stand B3.321; Laser Korea, in Seoul, July 5-7, stand 4101; and Laser World of Photonics China, in Shanghai, stand W2 2140, July 11-13. At these conferences, Coherent will showcase the most recent additions to its broad portfolio of differentiated solutions for materials processing. About Coherent Coherent empowers market innovators to define the future through breakthrough technologies, from materials to systems. We deliver innovations that resonate with our customers in diversified applications for the industrial, communications, electronics, and instrumentation markets. Headquartered in Saxonburg, Pennsylvania, Coherent has research and development, manufacturing, sales, service, and distribution facilities worldwide.

Read More

MANUFACTURING TECHNOLOGY

TPM Introduces State-of-the-Art Additive Manufacturing Lab in Greenville, SC

PR Newswire | June 02, 2023

TPM, a regional powerhouse in design and manufacturing solutions, today proudly unveils its innovative Additive Manufacturing Lab, a cutting-edge facility based in Greenville, SC. This state-of-the-art lab will serve as a regional demonstration center for industry-leading additive and 3D printing technology and provide outsourced 3D printed parts for the Southeast, underscoring TPM's unwavering dedication to fueling growth within the regional manufacturing sector. Equipped with state-of-the-art technologies from globally recognized manufacturers, including Markforged, HP, 3D Systems, Artec 3D, and AMT, TPM's new lab promises precision and quality. These resources position TPM to deliver exceptional services that embody efficiency and superior quality to its clientele. "Launching this newly renovated and enhanced additive lab is a key step as TPM accelerates growth in the manufacturing industry across the Southeastern region, providing the latest technology solutions to our clients." expressed Chris Fay, President of TPM. The lab's launch signifies a critical moment for the region's manufacturing prowess. It provides local manufacturing firms with tools to innovate faster, cut costs, and expedite time-to-market for their products. The Additive Manufacturing Lab comes to fruition in response to the burgeoning demand for 3D printing in the manufacturing industry. TPM's venture into this sphere reaffirms the company's faith in the transformative potential of additive manufacturing and its capacity to shape the trajectory of future production. This momentous announcement arrives at a critical juncture when manufacturers are actively exploring innovative avenues to refine their processes, bolster product quality, and maintain a competitive edge in a fast-paced, evolving marketplace. As TPM eagerly anticipates the possibilities this new lab will usher in, the company reaffirms its commitment to nurturing an ecosystem of innovation and growth for its valued partners. About TPMa TPM is dedicated to guiding manufacturing organizations through the journey of digital transformation by applying the latest software, hardware, and services, enabling people to maximize their potential, positioning companies for growth, and improving engineering processes.

Read More

MANUFACTURING TECHNOLOGY

NUBURU and GE Additive Sign Joint Development Agreement

Businesswire | June 02, 2023

NUBURU, Inc., a leading innovator in high-power and high-brightness industrial blue laser technology, today announced that it has signed a joint technology agreement with GE Additive, to explore the speed, accuracy, and commercial benefits of blue laser-based metal 3D printing. “As we continue to advance our proprietary blue laser technology, we have further increased both power and brightness to open up new applications,” said Dr. Mark Zediker, CEO and co-founder of NUBURU. “We’ve achieved key performance milestones that open new possibilities for significant advances in metal 3D printing. Working with GE Additive, and their expertise in metal additive manufacturing, will allow us to rapidly optimize our innovative area printing approach. That will accelerate the further expansion of our pioneering blue laser into innovative metal 3D printing solutions which have the potential to change the landscape of military logistics; aerospace manufacturing; medical device fabrication, and beyond.” “As an industry leader in metal 3D printing and having been on the leading edge of qualifying parts in regulated industries, we’re excited to evaluate NUBURU blue industrial laser technology and its benefits,” said Chris Schuppe, General Manager, Engineering & Technology of GE Additive. NUBURU’s novel approach to additive manufacturing is built on the foundation of blue light absorption by metals, a fundamental physical advantage that offers the highest efficiency laser-based melting for a wide range of industrially important metals. Combining the blue laser module with an innovative optical conditioning system, the NUBURU light engine is at the heart of the expected performance improvements. GE Additive will provide a powder bed system and expertise in the integration and characterization of this next generation prototype light engine, to quantify the performance improvements over existing technology. This joint development agreement is in addition to an agreement with GE Additive to support NUBURU’s previously announced AFWERX Small Business Innovation Research (SBIR) Phase II contract awarded to NUBURU in 2022. About NUBURU Founded in 2015, NUBURU, INC. (NYSE American: BURU) is a developer and manufacturer of industrial blue lasers that leverage fundamental physics and their high-brightness, high-power design to produce faster, higher quality welds and parts than current lasers can provide in laser welding and additive manufacturing of copper, gold, aluminum and other industrially important metals. NUBURU’s industrial blue lasers produce minimal to defect-free welds that are up to eight times faster than the traditional approaches — all with the flexibility inherent to laser processing. For more information, please visit www.nuburu.net. About GE Additive GE Additive – part of GE (NYSE: GE) is a world leader in metal additive design and manufacturing, a pioneering process that has the power and potential to transform businesses. Through our integrated offering of additive experts, advanced machines, and quality powders, we empower our customers to build innovative new products. Products that solve manufacturing challenges, improve business outcomes, and help change the world for the better. GE Additive offers Direct Metal Laser Melting, Electron Beam Melting and Binder Jet metal additive technologies, as well as AddWorks™ consulting services, software and metal powders. www.ge.com/additive.

Read More

FUTURE OF MANUFACTURING

Coherent Introduces New Laser Welding Head With Tactile Seam-Tracking Technology for Electric Vehicle Manufacturing

Globenewswire | June 01, 2023

Coherent Corp., a leader in advanced laser processing solutions, today introduced HIGHtactile, a new laser welding head with tactile seam-tracking technology ideal for electric vehicle (EV) manufacturing applications. The growing demand for EVs is expanding applications for lasers in automotive manufacturing, spurring innovations in process automation and improvements in laser usability. Coherent introduced HIGHtactile, a laser processing head with a new patent-pending seam-tracking technology that is easily configurable to perform highly automated fillet welding and brazing. “HIGHtactile is the culmination of twenty years of experience designing seam-tracking systems for welding and brazing, making it a truly unique product on the market,” said Dr. Karlheinz Gulden, Senior Vice President, Laser Components and Subsystems Business Unit. “Our laser processing heads have had great success in automotive manufacturing applications. Now, with the rapidly growing demand for electric vehicles, we are addressing a broad range of new opportunities in critical applications, such as fillet welds that enable battery trays to be stronger and stiffer while at the same time reducing weight.” HIGHtactile is extremely user-friendly, thanks to its wide range of embedded sensors that streamline almost every functional aspect of the welding head. The sensors improve process learning and enable faster laser processing. HIGHtactile can be configured to maximize performance for specific applications such as brazing steel or welding aluminum and steel. Those processes are typically found in body-in-white applications such as trunk lid and roof top brazing. HIGHtactile can be used with a wide range of lasers, wire feeders, and process monitoring systems. Coherent will exhibit at Laser World of Photonics, in Munich, Germany, June 27-30, stand B3.321; Laser Korea, in Seoul, July 5-7, stand 4101; and Laser World of Photonics China, in Shanghai, stand W2 2140, July 11-13. At these conferences, Coherent will showcase the most recent additions to its broad portfolio of differentiated solutions for materials processing. About Coherent Coherent empowers market innovators to define the future through breakthrough technologies, from materials to systems. We deliver innovations that resonate with our customers in diversified applications for the industrial, communications, electronics, and instrumentation markets. Headquartered in Saxonburg, Pennsylvania, Coherent has research and development, manufacturing, sales, service, and distribution facilities worldwide.

Read More

MANUFACTURING TECHNOLOGY

TPM Introduces State-of-the-Art Additive Manufacturing Lab in Greenville, SC

PR Newswire | June 02, 2023

TPM, a regional powerhouse in design and manufacturing solutions, today proudly unveils its innovative Additive Manufacturing Lab, a cutting-edge facility based in Greenville, SC. This state-of-the-art lab will serve as a regional demonstration center for industry-leading additive and 3D printing technology and provide outsourced 3D printed parts for the Southeast, underscoring TPM's unwavering dedication to fueling growth within the regional manufacturing sector. Equipped with state-of-the-art technologies from globally recognized manufacturers, including Markforged, HP, 3D Systems, Artec 3D, and AMT, TPM's new lab promises precision and quality. These resources position TPM to deliver exceptional services that embody efficiency and superior quality to its clientele. "Launching this newly renovated and enhanced additive lab is a key step as TPM accelerates growth in the manufacturing industry across the Southeastern region, providing the latest technology solutions to our clients." expressed Chris Fay, President of TPM. The lab's launch signifies a critical moment for the region's manufacturing prowess. It provides local manufacturing firms with tools to innovate faster, cut costs, and expedite time-to-market for their products. The Additive Manufacturing Lab comes to fruition in response to the burgeoning demand for 3D printing in the manufacturing industry. TPM's venture into this sphere reaffirms the company's faith in the transformative potential of additive manufacturing and its capacity to shape the trajectory of future production. This momentous announcement arrives at a critical juncture when manufacturers are actively exploring innovative avenues to refine their processes, bolster product quality, and maintain a competitive edge in a fast-paced, evolving marketplace. As TPM eagerly anticipates the possibilities this new lab will usher in, the company reaffirms its commitment to nurturing an ecosystem of innovation and growth for its valued partners. About TPMa TPM is dedicated to guiding manufacturing organizations through the journey of digital transformation by applying the latest software, hardware, and services, enabling people to maximize their potential, positioning companies for growth, and improving engineering processes.

Read More

Events