Problems in Aerospace Industry:
Design & Validation:
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Designing of Conceptual Models of Aircraft Components is highly time consuming &
high investment.
Prototyping of Full-Size Models with control boards, testing & validation of these
models also requires heavy investment of time & capital.
Conceptual Models & Prototypes have high risk of rejection and hence, high capital
loss.
Production & Customization:
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Aircraft Components have very large number of tools, fixtures & fasteners.
Production volumes in the aerospace industry are generally large and traditional
methods of production makes it difficult to cater to the increasing needs to
components.
Traditional production methods require large factories, high number of labors, and
heavy investments.
Customization of aircraft components to the specific needs is extremely difficult in
traditional methods. A complete model of and production line needs to be set up for
any type of customizations.
Applications:
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3D Printing technologies like Stereolithography (SLA) and Material Jetting are
used to produce high detail, smooth, scale models of aerospace designs.
Accurate models allow design intention to be clearly communicated and showcase the
overall form of a concept.
Prototyping Using 3D Printing enables full-size, high detail concept models for every
prototyping need. 3D printing allows for full testing & validation of prototype
performance.
This validation reduces the capital risk at the time of investing at the pre-production
stage.
3D printing for the production of aircraft components allows for the high-end interior
buildouts and high-speed production.
A single component manufactured through 3D printing weighs less and reduces air
drag by 2.1% reducing the fuel costs by 5.41%
3D printing allows for complete customization of components for any range of
production scale.
3D printing is capable of manufacturing highly complex geometric designs, and it
allows for the fabrication of complex and lightweight structures with stability.
3D PRINTING TECHNOLOGIES SUCH AS SELECTIVE LASER SINTERING
(SLS) AND BINDER JETTING ARE CAPABLE OF PRODUCING SMALL
BATCHES AT REASONABLE UNIT COSTS.
The table below summarizes the recommended materials for applications specific to the
aerospace industry:
Application Example part
Engine
Requirements
Tarmac nozzle Heat resistant functional
compartment bezel
parts
Cabin
Console
Customized functional
accessories
control part
knobs
Air flow
Flexible ducts and bellow
ducting
directors
Full size
Seat backs &
Large parts with smooth
panels
entry doors
surface finish
Air ducts
Recommended
Recommended
Process
Material
SLS
Glass-filled Nylon
SLA
Standard Resin
SLS
Nylon 12
SLA
Standard Resin
Casted metal Brackets and
Metal parts casted using SLA &
parts
door handles
3D printed patterns
Suspension
Consolidated,
wishbone &
lightweight, functional
Metal
components
Bezels
Lights
Castable Resin or
Material Jetting Wax
DMLS/SLM
GE Jet Engine metal parts
Dashboard
End use custom screen
interface
bezels
Headlight
Fully transparent, high-
Material Jetting
prototypes
detail models
& SLA
Titanium or
Aluminum
Material Jetting Digital ABS
Transparent Resin
Problems in Automotive Industry:
Automotive Brackets, Fixtures & Fasteners:
Automotive Industry deals with tonnes of vehicle components like brackets, fixtures &
fasteners, spare parts, etc.
Manufacturing of these brackets & spare parts through traditional methods requires huge
factories, intensive labor hours, high capital investments and yet runs short on supply.
Application:
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Automotive Industry uses advanced engineering materials and complex designs to
reduce weight and improve performance.
Using 3D printing, it is easy to design and manufacture these brackets & spare parts at
a desired scale.
3D printing enables complex geometric designs of brackets, fixtures & fasteners as
well as spare parts.
Automotive component parts are subject various testing like Temperature Tests, and
Moisture Tests.
3D printing enables faster production, higher design optimization & is cost effective.
Application of 3D printing in automotive industry also helps in incorporating extra
features like 3D Printed Logos and Brand Names, Printing Product IDs, QR codes and
Unique numbers.
The table below presents a range of materials that are used in the automotive industry along
with the associated application.
Application
Process
Material
Under the hood SLS
Nylon
Interior
accessories
SLA
Resin
Air ducts
SLS
Nylon
Full scale panels
Industrial
SLA
Resin
Cast metal
brackets &
handles
SLA & cast Wax
Complex metal
DMLS
components
Bezels
Material
jetting
Lights
SLA
Features
Example part
Heat resistant functional
Battery cover
parts
Customized cosmetic
Console prototype
components
Flexible ducting and
Air conditioning
bellows
ducting
Large parts with a
surface finish
comparable to injection Front bumper
molding that allow for
sanding and painting
Metal parts made from Alternator mounting
3d printed patterns
bracket
Consolidated,
Metal
lightweight, functional Suspension wishbone
metal parts
End use custom screen
Photopolymer
Dashboard interface
bezels
Fully transparent, high
Resin
Headlight prototypes
detail models