Special Report: Aviation Technology
3D printing a 'game changer'
September 1st 2013
Don’t look now, but pieces of that B787 Dreamliner that just landed didn’t come off the traditional production line of some parts supplier. They were printed using one of the fastest developing new technologies currently grabbing headlines, the 3D printer. Read More »
Indeed, Boeing already 3-D prints 300 distinct aircraft parts – most go on military jets - at a cost saving of 25% to 50% per part.
The Dreamliner has about 30 3D-printed parts, including environmental control ducts (ECDs) that carry cool air to electronic equipment. “Some of these ducts have complicated shapes and formerly had to be assembled from numerous pieces, boosting labour costs,” said Dan Seal, Boeing’s immersive development programme manager. ECDs traditionally require the costly production and assembly of up to 20 different parts, but can be 3-D printed in one piece.
More technically known as additive layer manufacturing (ALM), 3D printing is regarded as a game-changing technology that has the potential to revolutionize manufacturing. Computer programmed, it essentially “builds up” a component in layers from a variety of materials.
It can be used for a wide range of materials from metals to plastics, including composites, and is faster and more efficient than normal manufacturing processes. It uses less raw material and produces parts which are lighter, more complex and stronger.
“We’ve already seen 3D printing be used in a multitude of innovative ways all across Boeing,” said Seals.
Airbus is also using the technology. Both planemakers see weight saving gains from parts that are 3D printed because the components can be up to 65% lighter, but as strong as traditional machined parts, representing huge savings and reduced carbon emissions.
For every one kilogram reduction in weight, airlines save around $35,000 in fuel costs over an aircraft’s life.
Enginemakers are also excited about the potential. GE Aviation will produce the cobalt-chromium fuel nozzles in CFM International’s Leap engine with a 3D printer. The company will use a MakerBot printer to “grow” the part rather than assemble it using the previously required 18 components.
GE Aviation plans to make at least a $3.5 billion investment in 3-D printing to produce a host of parts at rates company officials claim will be 20 times faster.
Some analysts believe 3D printing will eventually revolutionize not only the production of aircraft – there have been suggestions giant printers could produce entire wings – but bring enormous efficiency gains across the industry. For instance, airlines would no longer have to maintain major parts stores, they could print what they required on the spot.
