Feature: Avionics
compared to expensive metal bearing moulds. They also enable a more agile manufacturing approach, allowing design engineers to test mould designs and easily modify them without incurring unfeasible production costs and high setup fees. In aerospace specifically, maintenance,
repair and overhaul are crucial growth areas for AM because it allows repair specialists to create replacement parts quickly and in small numbers. While 3D-printed mass-produced
bearings aren’t yet commonplace, 3D printing is making an impact in the rapid-prototyping world. For example, in a niche concept aeroplane design, 3D printing may be used to achieve fast and visually-appealing prototyping. This would ensure that the smallest parts function in unison with the entire system.
Lightweight designs Many industries have historically chosen to rely on lightweight metal innovations. Popular lightweight materials that have been used with AM in aerospace applications include advanced aluminium alloys, titanium alloys and composites. However, in bearing design
specifically, for low-load, low-speed applications, plastic bearings offer fantastic performance characteristics and are five times lighter than their steel counterparts. This reduces the initial weight and the energy needed to get them moving. In industries such as aerospace, lightweight design can achieve better safety performance as well as vital cost savings. Every component in the aeroplane
needs to deliver maximum value, including all of the hundreds of bearings found in a single plane. Bearings for aviation and aerospace have to withstand harsh conditions, extreme temperatures and demanding load profiles, while offering increased speed, reduced rotational torque and lightweight properties. Using 3D polymer-printing processes in
honeycomb-like structures, the component is lighter still. Tis would be very difficult and time-consuming to achieve with traditional machining processes.
Is quality standard? In June 2018, the Additive Manufacturing Standardization Collaborative (AMSC) published an updated version of its standardisation
roadmap for additive manufacturing. Adopting standards to mitigate and control risks as well as allowing more consistent quality are important steps for the future of 3D printing. This is especially important for components that are safety-critical such as bearings, and is essential to meet the aerospace industry’s stringent quality requirements. As with traditionally-manufactured
components, 3D-printed bearings must undergo rigorous testing procedures to make sure they are fit for purpose. Crucially, when experimenting with innovative new designs and enhanced material properties, it is essential that the final application environment is carefully considered, reaffirming the importance of bearing specialists in industry. In the traditional manufacturing
versus advanced manufacturing techniques debate, the good news is that you don’t need to pick a side. 3D printing can be used to supplement traditional manufacturing techniques, offering rapid prototyping and enhanced performance characteristics. And, whilst 3D-printed bearings aren’t
commonplace just yet, the evidence shows that they will be soon.
www.electronicsworld.co.uk October 2021 21
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