Computers & Software
greatest effect. SAVING partners - and other researchers - have considered parts like clips, brackets, hinges and latches. “Improving lots of parts, in a small way, can have a huge
effect,” he says. Demonstrating flexibility
The partners decided that a belt buckle would be an ideal part to demonstrate 3D printing’s flexibility and weight saving benefits - and was easier to relate to than a complex engine component. It was designed to look like a conventional buckle, and used similar design principles. But it uses far less material (as non-essential portions can simply be removed), as well as opting for laser-sintered titanium rather than steel or aluminium. “Titanium is easier to process in this way than steel or aluminium,” says Ayre. The titanium buckle would weigh 70g, rather than 155g
in steel. If a typical Airbus contains 850 of these buckles, the total saving would be 72.5kg - equivalent to 3.3m litres of fuel at a cost of around £2m. It might appear that the saving is simply down to using
lower-density titanium in place of steel, but Ayre believes that 3D printing has delivered two advantages over conventional techniques in this example. “We can vary the wall sections at will, which would be
very difficult with casting or pressing,” he says. “And the two components of the belt can be built in-situ, which means you remove the assembly cost.” Phill Dickens, professor of manufacturing technology at Loughborough University, points to another aerospace
example - a bracket for a TV set. A simple redesign can help to make the part thinner than before. But 3D printing can build it just as easily with an ‘internal lattice’ structure - so it is effectively porous. This offers huge weight savings, which has an effect for in-use costs. “You could save around $880,000 if you used this on just
40 seats,” he says. “And that’s just one part.” But he says that many practical issues must still solved if
3D printing is to become a true ‘manufacturing technology’. These include: developing a broader range of materials; minimising process waste; and ensuring repeatability. “There is also the issue of supports,” he says. “Supports
are a real pain.” Designing support
The support is the structure that is built alongside the actual 3D printed part that must be removed after the part is complete. The best way to exploit 3D printing is to design ever more
complex parts - which makes the issue of supports even more important. One possible answer, he believes, is to design the support
into the structure of the part, so that it effectively becomes a part of the design. “We have to do some really imaginative thinking to solve
this,” he says. Although we are still a long way from 3D-printed
aeroplanes, blood vessels and moon bases, increasing numbers of designers and manufacturers are already making use of this flexible and powerful set of technologies. ●
Exports of China-made moulds rise
September 2013. Held at Poly World Trade Centre Expo in Guangzhou, China, the fair aims to showcase 0supply chain and mould-making solutions and technologies for manufacturing-based industries. In 2012, China’s mould industry reached
T
some impressive figures due to increasing demand both at home and abroad. As a whole, the industry achieved
USD 20.69 billion in sales for the year, with US3.23 billion of that from export. Buyers from 188 countries and regions
imported China-made moulds in 2012. These numbers were made possible because of the domestic industry’s continued adoption of advanced machinery in mould production. Demand for advanced machinery
remains high in China, especially among manufacturers based across the Pearl River
12
www.engineerlive.com
he 2013 Asiamold, the Guangzhou International Mould & Die Exhibition, takes place from 24th–26th
Delta region. For makers of machine tools, consumer
electronics and moulded products, advanced machinery provided USD2.68 trillion in industrial output value during the first 11 months of 2012, with total sales volume equalling USD2.62 trillion With such a slim margin between total
output and sales volume, it’s easy to see that advanced machinery will continue to be in high demand among China’s manufacturers. Asiamold maintains efforts in being
the central platform for manufacturers to discover advanced machinery. As demand grows, suppliers of quality solutions can expect greater opportunities. More than 400 exhibitors are expected
to utilise more than 20,000 sqm of exhibition space. Additionally, due to the rise of mould and die makers within China, the 2013 show expects a 15 per cent increase in attendance from overseas. More
than 22,000 visitors are expected. Confirmed exhibitors will represent a
total of 15 countries and regions, including Austria, Belgium, China, France, Germany, Hong Kong, Israel, Japan, Korea, Malaysia, Portugal, Singapore, Taiwan and the US. Another objective for exhibitors is
showcasing emerging technologies. Additive manufacturing, a multi-billion dollar application will be the focus of exhibitors including Tianjin Vision Sensitive Technology, Magicfirm and Hangzhou Shining 3D Tech Asiamold is organised by Guangzhou
Guangya Messe Frankfurt in co-operation with EuroMold, the Hong Kong Federation of Innovative Technologies and Manufacturing Industries Limited and Guangzhou Die & Mould Industry Association. ●
For more information, visit
www.asiamold-china.com
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