Feature: Avionics


Exploring 3D printing in the aerospace industry


By Chris Johnson, Managing Director, SMB Bearings 3


D printing technologies have evolved signifi cantly over recent years, with much of the research eff ort happening in the materials science fi eld. T is


has enabled the development of a whole range of superalloys and high-performance polymers with superior mechanical characteristics. Additive manufacturing, or AM,


encompasses a range of technologies that create 3D objects by layering materials on top of each other. Each diff erent AM process impacts a material’s microstructure, including the size, shape and orientation of the grains or crystals. T is presents challenges and opportunities. In highly- regulated industries such as aerospace, the challenges are even greater, but technological advancement has seen a steady increase in adoption. For example, in 2020 Honeywell


Aerospace received a Federal Aviation 20 October 2021 www.electronicsworld.co.uk


Administration (FAA) certifi cation for its fi rst 3D-printed fl ight-critical engine component. T e component was a key structural part of the ATF3-6 turbofan engine found in the Dassault Falcon 20G maritime patrol aircraſt .


Design fl exibility 3D printing gives manufacturers the design flexibility to produce bearings with bespoke elements and enhanced performance. The 3D-printing process is relatively simple and doesn’t require expensive tooling. This allows manufacturers and design engineers to experiment with product features that wouldn’t have been economically viable using conventional manufacturing methods. Bearing manufacturers can use an


increasingly diverse range of materials with 3D printing. While metal 3D-printed components certainly dominate the aviation industry, we are


also beginning to realise the potential of 3D-printed reinforced polymers. In some instances the properties of these polymers surpass those of conventional materials, opening the door to exciting new design possibilities. For example, Boeing has qualified 3D


printer original equipment manufacturer (OEM) Stratasys’s Antero 800NA thermoplastic filament for flight parts. The material is tough and wear-resistant and has high strength, high heat resistance, low outgassing and superior chemical resistance. These qualities make it a good aerospace material and suitable for applications requiring durability and weight reduction. Another barrier to innovation


is minimum order volumes. 3D printing removes this barrier, allowing manufacturers to provide a cost-effective low-volume production service – even for orders as low as ten bearing units. 3D-printed moulds save time and money


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