Continuous Composites | June 16, 2022
Continuous Composites, a pioneer of advanced® composite 3D printing technology, has been chosen by NASA’s Small Business Innovation Research (SBIR) Program to additively manufacture low Coefficient of Thermal Expansion (CTE) open isogrid composite structures for space applications, using its patented Continuous Fiber 3D Printing technology, CF3D®.
In space, objects orbiting the earth experience drastic temperature changes when on the dark side of the earth compared to the light side. Therefore, precision objects such as satellites and optical benches require low to zero CTE to prevent warping or distortion from the expansion and contraction due to the significant temperature swings.
This NASA award will demonstrate CF3D’s advanced robotic steering of individual, continuous carbon fiber tows to print and test a flat 1.6’ by 3.3’ open isogrid rib structure, which will have a low CTE. CF3D printed isogrid structures can be deposited onto a support surface of many different shapes, including flat, cylindrical, spherical, conical, etc. The resulting part can be optimized for the desired strength and stiffness depending on launch and space loads.
CF3D allows for the manufacture of composite structures which are impractical to produce with traditional fabrication methods. One such structure is this open isogrid rib structure which has applications in many industries, including space and aerospace. By utilizing continuous fiber reinforcement, snap curing photopolymers, and advanced robotics, CF3D can drastically reduce the time and cost of creating open isogrid composite structures.
Given my background in composite design for space applications, I’m excited to demonstrate our unique fiber steering capabilities for this NASA project. This printed isogrid will have very little to zero CTE which is the goal for these types of space structures, his contract builds upon the work we have been doing in the DoD and commercial aerospace sector, and we’re excited to introduce our unique capabilities to the space industry.”
John Brendel, Application Engineer and technical POC on this NASA SBIR.
MANUFACTURING TECHNOLOGY,INDUSTRIAL 4.0
Embraer | July 01, 2022
Embraer has signed a contract with Toyota do Brasil to incorporate Toyota Production System (TPS) principles and concepts into its manufacturing operations. The initiative aims to reduce waste, improve operational efficiency, and generate more value for stakeholders.
During the first phase of this collaboration, a team of Toyota Brazil TPS specialists will immerse themselves in Embraer's daily operations to evaluate and suggest improvements for the company's main manufacturing area at the Ozires Silva Unit in So José dos Campos, So Paulo.
"Bringing Toyota to execute this work reinforces Embraer's commitment to focus on business excellence and sustainable growth, It will be an excellent opportunity to exchange knowledge and accelerate the usage of the Lean philosophy in the production systems, while strengthening practices already conducted by the Embraer Enterprise Excellence Program, the P3E."
-Francisco Gomes Neto, CEO of Embraer
Embraer has used the Lean philosophy as a business strategy to spread P3E principles, concepts, and practices since 2007. This program is in charge of leading transformations in an integrated manner, paving the way for the entire company to take significant steps toward improving its processes. This excellence system prioritizes safety first, quality always, and on-time delivery at the lowest possible cost.
Embraer, a reference in the concept of Industry 4.0, has made enormous progress at the forefront of manufacturing technologies with digital, integrated, and low environmental impact factories, with continuous process improvement and technology adaptation for people and operations. The company's goal is to become carbon neutral by 2022 and to have 100 percent of energy in Brazilian operations come from renewable sources by 2024.
Velo3D | July 13, 2022
Velo3D, Inc. (NYSE: VLD), a leading metal additive manufacturing technology company for mission-critical parts, today announced that Pratt & Whitney, a Raytheon Technologies business, has acquired an end-to-end solution from Velo3D to evaluate the Sapphire printer for manufacturing production jet engine components. This is the first Sapphire printer to be located at Pratt & Whitney; it previously utilized Velo3D’s contract manufacturer network to produce printed and finished parts.
Pratt & Whitney and Raytheon Technologies are experienced and accomplished users of Additive Manufacturing (AM) technologies with extensive knowledge across various platforms and applications. Raytheon Technologies is a launch participant of President Biden’s AM Forward initiative, a new program encouraging companies to explore the use of additive manufacturing to transform supply chains and drive innovation. Raytheon Technologies’ commitment includes seeking small-medium-enterprise manufacturers’ involvement in over 50% of its requests for quotes on products manufactured using additive technologies, as well as seeking to simplify and accelerate the procurement process of AM parts.
“Metal additive manufacturing can transform aviation and space systems by delivering unprecedented part consolidation, lighter weight components, and more efficient systems, We’re pleased to see Pratt & Whitney move forward with their own Sapphire XC printer. We’re eager to see how they innovate their most mission critical designs using the end-to-end solution and how the economies of scale of an in-house system help increase addressable use-cases.”
-Benny Buller, Velo3D Founder and CEO.
Pratt & Whitney looks forward to future applications using the Sapphire XC printer, and collaborations with other potential suppliers with the Velo3D capability, for Pratt & Whitney GTF™ and advanced engine programs, said Jesse Boyer, fellow, Additive Manufacturing, Pratt & Whitney.
The company’s new Sapphire XC printer is calibrated to print in Inconel 718, a nickel-based superalloy well-suited for extreme temperatures.
The Raytheon Technologies Research Center is the company’s central innovation hub where engineers, scientists and researchers explore and develop new, transformative technologies. The center provides the company’s businesses with groundbreaking innovations and solutions to critical customer problems in a wide range of research areas, including complex integrated systems, advanced materials and manufacturing, autonomy-enabling technologies, electrification, and sustainability.
This is made possible by Velo3D’s end-to-end solution, which includes Flow print preparation software, the Sapphire family of printers, Assure quality assurance software, and Intelligent Fusion underlying manufacturing processes. The system uses a set of known recipes to achieve the geometries desired without using supports and monitors the build process layer-by-layer to ensure the highest quality.
Velo3D is a metal 3D printing technology company. 3D printing—also known as additive manufacturing (AM)—has a unique ability to improve the way high-value metal parts are built. However, legacy metal AM has been greatly limited in its capabilities since its invention almost 30 years ago. This has prevented the technology from being used to create the most valuable and impactful parts, restricting its use to specific niches where the limitations were acceptable.
Velo3D has overcome these limitations so engineers can design and print the parts they want. The company’s solution unlocks a wide breadth of design freedom and enables customers in space exploration, aviation, power generation, energy and semiconductor to innovate the future in their respective industries. Using Velo3D, these customers can now build mission-critical metal parts that were previously impossible to manufacture. The end-to-end solution includes the Flow print preparation software, the Sapphire family of printers, and the Assure quality control system—all of which are powered by Velo3D’s Intelligent Fusion manufacturing process. The company delivered its first Sapphire system in 2018 and has been a strategic partner to innovators such as SpaceX, Honeywell, Honda, Chromalloy, and Lam Research.