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    Lecture 16 Part 1 Application For AM Final

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    Lecture 16 Part 1 Application For AM Final

    Uploaded by

    shanur begulaji
    64 views22 pages
    am

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    Lecture 16 Part 1 Application for AM Final

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    am

    Copyright:

    © All Rights Reserved
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    Download as pptx, pdf, or txt
    64 views22 pages

    Lecture 16 Part 1 Application For AM Final

    Uploaded by

    shanur begulaji
    am

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 22

    Chapter 16

    Part 1: Application for Additive Manufacturing


    Contents

    1. Introduction
    2. Aerospace
    3. Automotive
    4. Biomedical
    5. Conclusion
    6. Questions and Discussion
    1 . Introduction
    • This process has revolutionized the way we think about design and
    manufacturing

    (Source: WMTR.com)

    • AM process produces any complex parts without the need of traditional tools

    • Another Advantages: Rapid Part Turnaround, shorten design time, reduction


    in material waste, limited tooling required, reduced labor cost

    • That is the reason this technology has received great attention from various
    industrial sectors such as aerospace, automotive, biomedical
    • Applications of Additive Manufacturing

    Applications Examples

    • Design Tool Optimization


    • Design Iteration
    Rapid • Geometric Fit-checks
    Prototyping • Scale Models
    • Working Prototypes
    (Source: America Makes)

    • Injection Molding

    • Custom Fixture
    Rapid Tooling • Injection Molds
    • Trimming Tools
    (Source: Javelin
    Technologies)
    Applications Examples

    • Printed Assemblies: GE Fuel Nozzel


    • In-house Manufacturing
    Rapid
    • Printed Assemblies
    Manufacturing
    • Legacy Part Development
    (Source: GE)

    • Part Repair: Aerospace Part


    • Machining Errors
    Repair • Casting Errors
    • Worn Parts
    (Source: MRO)

    • Electronics Chip: Inkjet Technology

    • Embedded Sensors
    • Structural Health
    Electronics
    Monitoring
    • Printed Electronics
    (Source: 3D Printing
    Media Network)
    2. Aerospace

    2.1 NASA
    • NASA has extensively been working on AM
    techniques whether it could be tools or even
    complete space rocket.
    (a) Plastic

    • The international space station’s 3D


    printer has successfully manufactured 3D
    printed objects in space shown in Fig. 1.
    • The experiments have demonstrated that
    3D printers work normally in space too!

    Fig. 1 International space station 3D


    Printer. (Source: NASA)
    (b) Metal

    • NASA has developed 3D printed


    rocket engine part at NASA’s Marshall
    Space Flight Center in Alabama.
    • they have produced engine with the
    75% of metal-AM parts as well as
    full-scale copper rocket engine parts
    as shown in Fig. 2.
    • They are further expecting to build
    nearly 100% 3D Printed Jet Engine
    which will serve as a prototype Full-scale copper rocket engine part.
    (Source: NASA)
    similar to the commercial design.
    2.2 Airbus Defense and Space

    • The Airbus Defense and Space division has


    successfully produced record-breaking
    fully Electric Satellite using 3D Printing
    technology.
    • They are leading supplier of Satellite and
    also largest aerospace company in the
    world.
    • Satellite for space application is very
    complex in shape and needs to withstand
    tremendous temperature difference and
    Telecommunication satellite. (Source:
    external force involved. Airbus Defense and Space)
    • More examples..

    • AM produced robust titanium • Nacelle hinge bracket produced by


    brackets have successfully AM. (Source: Airbus Defense and
    withstood high temperature and Space)
    external forces in space. (Source:
    Airbus Defense and Space)
    2.3 RAUG Technology Company

    • RAUG is a Swiss technology company


    working in the fields of Defense,
    Aerospace, and Security.
    • RAUG has developed Antenna Bracket
    for RAUG’s Sentinel Satellite using AM
    technology.
    • The Antenna Bracket is topologically
    optimized to reduce the weight of the
    component by 40% (reduced from 1.6
    The topology optimized antenna bracket for
    Kg to 940 g). Sentinel satellites. (Source: EOS)

    • Every gram saved reduces the launch


    costs as system required less fuel for
    the ascent.
    2.4 General Electrics (GE)

    • GE is one of the best known for the


    incorporation of 3D Printed parts in Jet
    Engines.
    • GE has produced fuel nozzles using
    Selective Laser Melting technology as
    shown in Figure.
    • This resulted in reduction in number of
    parts required to print from 18 to 1 and
    reduction in weight by 25%.
    • It has reported that LEAP engine using
    these fuel nozzles are approximately 15%
    AM produced fuel nozzle for the LEAP
    more efficient than their counterparts. engine. (Source: CFM International)
    3. Automotive
    Need of Additive Manufacturing in Automotive Industry

    • To develop the parts with sustainable energy efficiency, driving advances in vehicle
    design, the reduction of CO2 emission, and reduction in cost.
    • Moreover, there is also a stringent requirement to meet customer-specific solutions.
    To achieve those goals, traditional manufacturing cannot be used profitably as it
    possesses the limitations.
    • In a current scenario, AM technologies have advanced a lot where we can produce the
    end-use parts (both plastic and metal) with the desired requirements.
    • In 2014, Deloitte study has shown the benefits of AM for automotive for two main
    sources:
    (i) Product Innovation and
    (ii) Supply chain transformation.
    • This is because of advantages offered by AM such as faster development cycle, light
    weighting, part consolidation, and ease in production of new and custom
    geometries.
    3.1 FORD

    • Ford Company has been using AM technology since 1988 and it has more
    than 90 numbers of 3D Printers installed to use in global operations.
    • Recently, Ford has announced their investment in AM technology by $45
    million.
    • Applications involved are from spare parts for their own production lines
    to new parts.
    • Ford is aiming to reduce the cost of a road usable car by 70%.
    • Some examples..

    Additively Manufactured Raptor


    Additively Manufactured Mustang GT500 electric
    auxiliary plugs created for a niche
    parking brake bracket. (Source: Ford)
    market. (Source: Ford)

    Additively Manufactured Focus HVAC lever


    arm. (Source: Ford)
    3.2 BMW

    • BMW group is leading pioneer in AM technologies and has been working with
    AM since 1990.
    • They have produced more than 1 million parts using AM since 2010.
    • They are into both metal as well as plastic 3D printing and uses this
    technology for both prototyping and development purpose.
    • For example, new BMW i8 Roadster’s weight has reduced and strength
    improved using AM produced parts.
    • One of the parts is a window guide rail for BMW i8 Roadster manufactured
    using Multi Jet Fusion technology of HP.
    3.3 Other OEM companies

    • GM, Chrysler, Honda, Volkswagen, Toyota, and various other OEMs are
    focusing more on AM technologies and enhancing their operations using 3D
    printing.
    • Volkswagen uses this latest 3D printing of HP metal Jet which is the Binder
    Jet technology for mass production.
    4. Biomedical

    • AM technologies offer many potential benefits in comparison to the


    traditional manufacturing technologies mentioned as follow:

    1. Ability to produce patient-personalized complex implants obtained through


    patent’s Computed Tomography (CT)/ Magnetic Resonance Imaging (MRI)
    data,
    2. Unique customized, fast service for individual patient,
    3. Ability to produce complex shaped implants with the scaffold structure as
    per requirement,
    4. Support the tissue growth,
    5. Shortens the surgical time and increases the success of the surgery,
    6. Improve the implant fixation,
    7. Reduces the risk of repeated surgery,
    8. High material utilization, and
    9. Reduce the delivery time and cost.
    • The AM technologies are widely getting adopted for producing the
    biomedical parts such as knee and hip joints, implants, and dental areas.
    • Various researchers have shown that fabricating implants using AM
    technologies have positive effect on promoting the tissue generation.

    • Some examples..

    (a) Three dimensional shoulder joint Selective laser meted Acetabular cup
    simulation data including the design as made up of Ti-24NB-4Zr-8Sn alloy.
    well as position of plate and screw. (b)
    Three dimensional printed model of the
    same. (c) T-shoulder joint radiography
    after surgery.
    • FDA cleared 3D Printed biomedical applications
    5. Summary

    • Additive Manufacturing has successfully been implemented in various


    industrial sectors, such as aerospace, automotive, biomedical, etc.

    • Additive Manufacturing has revolutionized the way we think about


    design and manufacturing.

    • This process has expanded from prototyping to direct tool


    manufacturing to production and has been rapidly expanding over last
    five years to include various applications.
    Thank You!

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