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The dual overlapping laser technology developed and patented by SLM Solutions enables two lasers to work simultaneously on the part in the overlap area, producing not only a faster build but a larger part as well. The company carried out tests on these overlap areas showing there is no difference in quality between the area built exclusively by one laser and the area in the overlap worked on by both lasers interchangeably. SLM Solutions engineers went through sev- eral iterations to prepare the fi le and build some sample test pieces to see if the job could achieve the customer’s goal of cost and time savings, as well as weight reduction.
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Titanium aerospace blades were manufactured by Sintavia LLC (Davie, FL) using SLM 280HL 3D printing technology from SLM Solutions (Novi, MI).
In general, aerospace/aircraft requirements for inspection
are quite extensive, usually involving a computed tomog- raphy scan, a nondestructive test method, to check for porosity or voids in the part, or the customer may perform destructive testing by cutting up the part. “We used nonde- structive testing on this part, then performed a real-world test by mounting it on an engine in its intended use, and running it until it failed,” Hansen said.
A Division of:
While 3D printing tends to get attention for its ability to build unique geometries, the nature of this aircraft component was not particularly complex. However, manufacturing a part of that size in titanium in such a short time was something that could not have been achieved had the part been ma- chined out of a billet. “With additive manufacturing you’re not restricted to traditional tools and machinery, so you can design in more organic shapes and the entire cycle of designing and engineering a critical part for the aircraft industry is condensed considerably,” Hansen said. According to Richard Grylls, head of the applications engineering department/North America technical director, “The part’s size meant that it would have taken several weeks
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AdvancedManufacturing.org | February 2017
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