The aerospace industry was one of the first industries to invest in 3D or additive manufacturing technology back in the 80s. Initially, it was utilized because of its ability to create various aircraft parts and components, such as aircraft engine mounts and exhaust components. However, now it has evolved to cover multiple other technologies as well. A clear value proposition of the 3D manufacturing process is that it produces stronger and lighter parts than the ones developed through traditional manufacturing.
3D printing finds its applications and uses in cases that vary across industries but generally include tooling aids and visual and functional prototypes. In this blog, we will present an overview of the benefits and uses of 3D printing in the aerospace industry:
The Benefits of 3D Printing for Aerospace
Low-volume Manufacturing
Low-volume manufacturing is a specialized service that allows the production of high-quality parts but in low volumes. You will not have to invest in expensive tools to develop test objects because 3D printing will enable you to create complex geometries cost-effectively. Original equipment manufacturers, commonly known as OEMs, and suppliers can produce parts and components at a low cost and in small quantities, thanks to 3D printing.
Weight Reduction
Weight is an important factor in any design process as it directly affects the functional and operational aspects of aviation products. There is a prominent reduction in carbon emissions, fuel consumption, and payload due to weight reduction in part manufacturing processes because it has significantly reduced the weight of 3D-printed objects. This has contributed to lowering the negative impacts of manufacturing processes on the environment.
The 3D design technology has allowed considerable fuel-saving and has proven to be a great alternative for creating lightweight parts. The potential to increase the complexity of parts is limitless due to design optimization tools such as generative design software that allows designers to collaborate with AI (Artificial Intelligence) algorithms to generate and evaluate numerous product design ideas.
Material Efficiency
Material efficiency means having a lower production volume by using less materials to make parts and components of any equipment, in this instance, aircraft exhaust systems, engine mounts, etc. Since the 3D printing process allows you to create parts one layer at a time, therefore, it generates less waste as opposed to the traditional subtractive methods. You can use various materials for this particular service ranging from engineering-grade thermoplastics to high-performance metal powders. The range of materials available for 3D printing is constantly broadening, effectively unlocking advanced aerospace applications.
Parts Consolidation
Is a process that allows you to combine multiple parts into a single component and allows you to make necessary design changes without compromising the functionality of the final product. Reduction in the number of parts required can effectively simplify the products assembly and maintenance process as it reduces the amount of time needed for process completion.
Maintenance & Repair
An aircraft has an average lifespan that can range from 20 to 30 years, making their MRO, i.e., maintenance, repair, and overhaul, an essential function in the industry. You can weld, repair and restore aviation equipment and faulty parts of an aircraft using metal 3D printing technologies such as Direct Energy Deposition; other high-end equipment can also be repaired by adding material to its worn-out surfaces.
Applications In Aerospace
The four major applications of 3D manufacturing in the aerospace industry are:
1.Jigs And Fixtures:
Produce customized tooling equipment such as jigs, fixtures templates, and gauges on demand.
2.Surrogates:
Placeholder parts used during production or training in place of components that are installed later in final assemblies.
3.Mounts:
Manufacture structural components such as low-volume metal brackets that are used to mount engines.
4.Visual Prototypes:
Produce physical prototypes allowing designers to get a better understanding of the form and fit of a particular part before production starts.
Aerospace makes up a significant proportion of the 3D manufacturing market because it provides enormous value, from improving aircraft performance to offering a more efficient approach for producing end-use parts, physical prototypes, reduce lead time, limits storage space, is cost-effective, and reduces the number of materials wasted during production.
About Acorn Welding
Acorn Welding is the most trusted and highly qualified aviation welding company in Edmonton. We have the latest product designs and manufacturing capabilities required for safe aircraft welding. To find out more about our product manufacturing services, contact us today.
