Digital Thread for Additively Manufactured Aviation Parts
Design, engineering and manufacturing practices are changing rapidly and the industrial base is relying on digitizing their processes to bring aviation components to the customer faster than ever. In addition, advanced manufacturing technologies such as Additive Manufacturing (AM) facilitate on-demand production of components. The additive manufacturing industry continues to grow with new machines, faster processes and a large selection of materials. This presentation will outline the new commercially available tools that are used to design and manufacture aviation systems and take advantage of lightweight designs with lattice structures. A special Technical Data Package (TDP) is required for Additive Manufacturing (Design model with PMI, AM stock model, 3MF files for lattice structures, AM tray model with part orientation and nesting, post processing CNC Assembly, etc.) to implement the digital thread for end to end solutions. The redesign, manufacturing process and the TDP set will be demonstrated with a set of aviation components.
Andreas Vlahinos - Advanced Engineering Solutions, George Barnych - NCDMM — National Center for Defense Manufacturing and Machining, and James Metzger - Utility Helicopters Project Office
Optimized Metal Designs for a Ship to Shore Transport
Big Metal Additive has built and tested a ship-to-shore transport for two full sized ISO shipping containers. We used generative design and industrial scale hybrid metal additive manufacturing to create several key structural elements of the ship-to-shore transport. Generative and optimized designs are powerful capabilities to create efficient structures that express a new level of performance. Optimized designs are often 3D printed at small scale; however, large scale metal AM can produce these designs for industrial applications such as automotive chassis, architectural beams and even Naval vessels. This presentation will present a case study of how generative optimization is applied to a ship-to-shore transport. The power of large-scale metal AM is rapid production of design candidates for practical evaluation in real world environments. As new subsystems become available (energy storage, sensors, power transmission, etc.) a system level designer will want to explore new architectures for creating efficient products.
Slade Gardner and Ryan Manning - Big Metal Additive
Novel Additive Manufacturing Processes for Industrial Precious Metals in the Glass Industry
The presentation will focus on the development of additive manufacturing equipment and processes for precious metals for the glass fibre industry. Challenges regarding the use of precious metals for additive manufacturing, as well as the unique opportunities associated with additive manufacturing of precious metals (up to 380,000 USD/kg) will be discussed. Furthermore, a case study of the glass fibre industry and the respective developments will be presented in detail. The audience will gain unique insights into the full adaptation from concept to industrial implementation of a completely new additive manufacturing process chain.
Thilo Becker - Institut fur Textiltechnik of the RWTH Aachen University