MATERIALS • PROCESSES • FINISHES
Modern machines can manufacture increasingly complex parts to a high standard
be done using blown powder technology, which uses a laser to create a melt pool in the initial solid material (as opposed to powder) and then uses a nozzle and a carrier gas to ‘blow’ metal powder into it. By moving the component, or the nozzle (or both), additional material can be added to the original, creating a 3D component. This technology is a derivative of laser cladding and has many similar characteristics to welding, but has the advantage of far greater control, with consequently minimal It is possible for certain designs to be
made much more cheaply than using traditional manufacturing processes. For example, if a company wanted to produce a 300mm diameter stainless steel pipe, which could be available needed to have integral handles or other additional features, they would normally have to purchase a solid block or perhaps a pipe with far greater wall thickness than required. This would then need to be machined away. Using blown powder techniques, the manufacturer
can use standard raw material and simply add the additional features without compromising metallurgical, structural and dimensional integrity.
DESIGNING FOR THE AEROSPACE INDUSTRY When it comes to deciding which parts to 3D print, most aircraft makers are reluctant to share information with competitors. Although it is clear that certain parts can create more value added through printing than others, it is sensible to start with parts that are less critical and gain experience of designing for this manufacturing technology, before moving onto more challenging components. To utilise 3D-printing technologies to the full, a change of mindset is required. To date, much of the innovation activity in the aerospace industry has focused on incremental changes – small steps that
are intended to reduce waste, minimise use of space and conserve fuel. This approach is considered ‘safe’, as it can previously are more likely to do so again However, the potential of 3D-printing technologies can’t be fully realised by simply copying what has gone before and design engineers need to start rethinking their approach. Modern additive machines are capable of manufacturing increasingly complex metal parts, to a high standard and with improved structural properties. Some of these designs would be impossible to make any other way. With the backing of improved software and a more open-minded approach to design and should become a standard part of aerospace manufacturing programmes in the future.
Ian Joesbury is a vice president of the Institute of Mechanical Engineers and a senior consultant at Vendigital. For more information visit
www.vendigital.com
www.engineerlive.com 27
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