I’ve written that the military is researching alternative fuels. (Here and here, for starters.) Primarily because the logistics of getting fuel to the front is problematic- not only is the journey often difficult, but troops are put at risk defending that transport. Well, that’s also why the military is examining the use of 3-D printing- so that critical components can be at the front. Not only can they be made available quickly- the need to inventory various parts is moot, since they can be printed on demand. Unfortunately, the CAD (computer-aided design) software and CNC (computer numerical control) machining technologies are still complex- so we won’t be seeing this technology on every forward base just yet.
But, if we design our complex parts knowing we will be replacing/repairing systems with 3D printed parts, then our designs can incorporate these technologies and, at least, try to make the systems less complex. That is exactly what EADS (EADS Innovation Works division), the European conglomerate, is doing. (EADS is an acronym for European Aeronautic Defense and Space Company N.V.)
The system they are employing includes a laser scanner (Faro Scanarm), imaging and reverse engineering software (Geomagic), and an Arcam A2 electron beam melting 3D (additive layer manufacturing) system. The goal is to use these processes for the Airbus (civilian and military), Eurocopter (military and civilian), as well as other business units.
Right now the effort is “proof-of-concept”. If the parts have the designs “on file”, then no scanning is needed, and they can be produced at the same location they are required. But, in case not all the parts are in the memory, each location would have a 3D scanner, the reverse engineering Goemagic software, and a 3D printer.
The process is fairly simple. The laser scanner records data at 20,000 points per second (0.035 mm accuracy). These scanner images are then reverse engineered with the Geomagic software. This is basically step 1 of the process.
This model, produced by the Geomagic software is then coalesced (removing scanner noise and outliers) and adjusted (using “curve sampling” tools) to insure that the manufacturing process can, indeed, produce the desired part. (This means that the point count must be reduced to a manageable size; think of it as the way music is changed from the complex form that exists in the studio to an mp3 type product.) The scan is then saved as an STL file (which is the type used by the 3D printer). [Note that if the part is fully characterized by a CAD model, then these two steps are not needed; the STL file is simply used to produce part, as would happen in the next step.]
The third step is the production of the part. The model is sliced into a multitude of cross sections (0.1 mm or so) and then printed, layer by layer, until the part is fully “built-up”.
Another key advantage of this process is that machining should be obviated. No environmental waste, as would happen as the parts are honed into “perfect shape” are produced. Moreover, only the necessary raw materials are needed- they are coalesced into the final part, further reducing the need for storage at the forward location.
Ok you know I love your 3D printer posts. The inner geek and artist in me just drools at the possible things I could do with one. This post is shared far and wide…More cool reasons why 3D printing is going to be a part of an awesome future.
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Wait a few more day, Lisa… I have had a whole bunch hiding in my queue! Because the “explosion” of apps is nigh…
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true 3d printing is one of the technology will have to be developed, given the benefits are very good for us. redraw logo
It actually is developed. It needs refinement- and reduction in costs.
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I know a couple guys that do CAD.
Marie Loerzel recently posted..My Codependent Relationship
They probably love this stuff, Marie!
So this is interesting. These technologies would require the government to increase spending on R&D? Good, yes? LIke the idea of developing the alternative fuels also….
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One thing we know for sure, Alessa. If and when we get this process down pat, we can cut the need to warehouse parts in forward locations- and can keep our equipment working – at least until the next delivery of critical components.
Thanks for the visit.
This type of technology totally blows me away. I would think that once we are over the hump of having this work correctly it would save us so much money in the long run.
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One can only hope that is true, Shawn.
I wonder how many lawsuits will ensue as this process becomes more widespread (for copyright and patent infringement)?
Roy, it strikes me that so often the military gets money to do things in the name of defense etc and they make things happen that scientists seem to struggle to make happen. Now I wonder, what would happen if cancer became a military battlefield or starvation or abuse. So many wonderful inventions exist because of military ingenuity
Well, Roberta, I can only guess. After all, we’ve had problems with mental health forever, but now that PTSD is being recognized as a military trauma, great innovations are coming. Just like the TBI (traumatic brain injury) developments (but the NFL may not be happy about that development).
I totally admit it, additive manufacturing might be the only sustainable way for the future of mass production as well. Nowadays it is usually used in rapid prototyping, but the evolution is really fast. A desktop 3D printer is already affordable for many people, which print with plastic filaments, but there are already 3D printers which can print with metal or ceramics as well. Printing with composite materials leads to unbelievable progression in space technology as well, and of course, the military forces invest thousand billion dollars in the research of 3D printing.
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You are absolutely correct in that last statement, Peter.
I am not quite sure that desktop 3D printing will be all that pervasive, unless inexpensive designs are offered the public. (I don’t see the general populace preparing their own STL files any time soon- at all.) And, it is not clear that a 3D scanner will be cheap- nor will it not require “clean-up” of the images prepared. So, in my book, that jury is still out.
I’ve been writing lately about the progressio of steam, engine development back in the 1700s – what would they have made of 3D printing I wonder! (I suspect the inventors would have loved it, the establishment would have called it witch craft!)
Cheers,Gordon
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We seem to forget how each novel invention ran into the same resistance, problems, and development issues as do the ones we recognize as most modern developments, today.
Great addition to the discussion, Gordon! Thanks so much for bringing up that salient point.
It will really benefit for us !! 3d printer means it’s updating version of print !! which is interesting to watch !! I hope it will work too fast !!! Thanks…
Me, too, VinylStickers!
Because being able to make what I dream up in a jiffy means I can test it better and faster- and at less expense!
Thanks for the visit and the comment.
I wonder how far we are from 3D printing people like in The 5th Element. Hah.
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Well- given the quality of some of our elected officials- that may be a valid explanation!
DLM metal 3d printers like Arcam that you’ve mentioned are unfortunately too expensive yet, although I still think that the real industrial evolution happens in factories where traditional subtractive fabrication methods like cnc milling will be replaced by additive machines like EOS or Arcam. Consumer desktop 3d printers are just toys for makers as I saw it at the TCT Show…
bonooobong recently posted..3D nyomtatás kiállítások világszerte
Yes, some of the processes are pretty expensive… But, as you said, some of them are really coming into play…
Thanks for the visit and the comment, Peter…
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When I originally commented I clicked the
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I am sorry that happened. I will fix it accordingly.
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