Airbus and Boeing are each evaluating the use of 3D printing to make their aircraft. And, GE, which makes the engines is also considering the use of the process. There are three reasons these- and other- folks want to produce airplanes via 3D printing.
- It’s far more efficient (less waste and more precise control) printing complex shapes. There is no need to join parts together with connectors or bolts.
- 3D printing allows one to vary the internal structure- strength where it is needed, lightness where it is not. This obviously saves weight. And weight requires thrust. And thrust requires fuel.
- 3D printing lets one mix materials during printing. (Right now, only Objet has a printer to do so; but this feature will be more common in the future.)
Airbus is currently working on a concept airliner (kind of like the concept cars the automotive industry shows at car shows) it hopes to start selling in 2050. And, the concept relies upon 3D printing (additive layer manufacturing). Bastian Schafer (cabin designer, one of 10 industrial designers working on this project) believes that the new airplane can be about ½ to 65% as light as existing plane, if the 3D printing concept is employed. Moreover, this concept plane is a little “different”- a transparent skin is being considered, which will give the passengers a full view of the sky and clouds about the plane. This concept program is enabling Airbus to use the 3D printers to create parts for the A380- parts that are stronger and lighter than those made with conventional techniques. (Of course, the concept plane is based upon the 3D printer being able to print 80 m X 80 m parts! The current printers are barely packing in 2 m X 2 m parts, and those take days to create!)
But, that’s almost 40 years away. Right now, GE is using 3D printing systems to make lightweight engines. CFM International ( a joint venture between GE and Snecma, a French firm) is designing parts for it’s “Leap” turbofan engines using additive manufacturing. The engine has a 30% lower weight and material needs of 30 to 40% below those made via conventional techniques. These engines will, therefore, be more efficient.
[These turbofan engines combine gas tubines with ducted fans that accelerate the flow of air through the engine. The amount of air that can bypass the engine core compared to passing through the engine is called the bypass ratio. If more jet thrust when compared to fan thrust is used, the engines are termed low bypass turbofans; those that have higher fan thrust are called high bypass engine. Military engines are typically low bypass; commercial aviation use high bypass engines, because they yield the best performance for speeds of 500 to 1000 mph.]
And, 3D printing is perfect for the airplane wing- which is being considered by many of these firms. It is basically hollow with struts to provide strength, stability, and structure. Similar to the bones in a bird wing. To make this wing now takes lots of little parts, plus an assortment of nuts and bolts. These nuts and bolts add weight to the wing- and are potential points of failure. Not so, if this wing were produced via 3D printing. Where every strut is connected AS it’s formed, producing a single piece structure, all connected, and of very low weight. Strong where it needs to be strong and light where it needs to light.
By using additive manufacturing, there is no need to braze 15 or 20 parts to form one component. Brazing is similar to soldering metal parts together, but the temperatures involved in melting the components together are much higher . And, like soldering, this is a process that can fail; additive manufacturing obviates these failures and makes the parts lighter, since no filler to join the 15 to 20 parts is necessary. And, every pound of weight saved in producing the plane is a pound of thrust that is not needed to keep it aloft- which means energy usage is dramatically reduced.
Wow this is really impressive!! The first time I saw 3-D printing in use was for the construction industry. I watched as the building floorplans were used to create the smaller models you may have seen used for demonstrations or sales presentations before a new building has started construction. The models created during the “printing” process even had moving parts and the colors for the real thing!
I hadn’t thought of this process being used to design an airplane; but it makes a great deal of sense. As the number of companies still creating large commercial aircraft has declined; the industry has become even more competitive. Techniques like this, that can reduce the time and expense of the design process are not just a “nice to have”, they are a requirement.
Peggy recently posted..The Journey to Becoming a Lady Rider…
Peggy:
I was amazed when I saw this technology used for concrete! And, yes, the moving parts and different colors really makes limited production runs and prototype development potentially a much simpler process.
Thanks for the visit AND the comment.
As you know I am fascinated with the 3D printing articles you’ve published, and this one is no different. Since I’ve raved about it before I’ll share the story this puts me in mind of.
My maternal Grandfather served in the Army Air Corps, in the 40’s during WW2 as a staff sarg. in charge of fighter plane repair. He was so good at his job, that Jimmy Stewart’s squadron came in for repairs and Grandpa’s team was requested to do them. Grandpa then personally trained some of the men to do in flight repair work (minor) and emergency ground repairs ect. Mr. Stewart, before leaving, walked up to my Grandpa, shook his hand, and said he never felt safer in the air than he did knowing Grandpa had taken care of his unit. Of course, Grandpa was honored, as he told the story he grinned very humbly. After the war he was offered several jobs in the blossoming industry of the commercial air, but turned them all down. When I asked why, he said, “I would have had to travel a lot by plane.” I said, “So…” He said, “I can fix them, I know what all can go wrong with them, I never flew, and I never want to.”
🙂
Perhaps with this new technology in hand we won’t have sooooo much to worry about, and had Grandpa lived long enough to see it, he would have felt the same.
Thank you always for your posts!
Lisa Brandel recently posted..The Painted Lady by Lisa Brandel
Loved the anecdote, Lisa…
But, I think your grandfather was worried what the other mechanics would (not) be doing…
Roy
This technique is amazing, Roy. Eliminating not only nuts and bolts but also the welding material is a very pragmatic way to reduce the weight and increase efficiency. Transparent skinned airplanes are even more amazing. I get altitude feelings just by imagining myself in one of those (if I reach to those times, of course).
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Gustavo:
I’m with you. I may love flying- but I’m not sure how comfortable I will be flying around the world in a thunderstorm in a transparent airplane!
ED printing was really amazing gadget when they released it because now you can see the picture just like a natural when you see in personal..
Fatima Hipolito recently posted..Dr. Laitman
Yes, it has been amazing, Fatima…
One of the biggest impeti now is the US Military- which determined that using these devices can cut their risky resupply efforts- letting the troops “print” replacement parts as they need them.
So true Sir Roy, That’s why we can say thanks to the man who build this, because there’s no risky Life anymore..
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I’m so glad you liked this post, Fatima!
Thanks for the comment.
Yes sir jens I appreciate you post in here, I love it…
Fatima Hipolito recently posted..Laitman
Thanks, Fatima!
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I’m glad you found the post of interest. Thanks for the comment and the visit.
Yes of course 3D printing is a complete visual of a image. And it is very impressive. 3D printing is really very attractive. Now a days everyone using this kind of printing and also like. Very good article. Happy to read it.
3D printing (ok, additive manufacturing) is making us reconsider our entire product design process.
Of course, much of the promise is still unkept… but, the allure of what it can do is exciting.
Thanks for your comment and visit, Neeraj.