3D printing and additive manufacturing are making waves all over the world as industry after industry begins to adopt and experiment with these new technologies. The use of 3D printing in the aerospace industry is already transforming the way components are designed and built, with more anticipated changes on the horizon as major aircraft manufacturers and beyond discover innovative applications for 3D printing in aviation.
Applications of 3D Printing in Aerospace
Additive manufacturing and 3D printing technology will play an important role in the future of aerospace manufacturing. One could argue that these technologies are still in their infancy, but many applications for 3D printing in aerospace can already be observed, from prototyping to strategic consolidations.
Rapid Prototyping
3D printing is much faster than some traditional aerospace manufacturing techniques, which is incredibly valuable at the prototyping stage of product development and aircraft design. Fast prototyping, empowered by 3D printing technology, allows aerospace companies to iterate on new ideas more efficiently, so they can put new innovations into practice sooner and stay ahead of the competition.
Weight Reduction
Leveraging 3D printing in the aerospace industry allows aircraft manufacturers to experiment with more weight reduction strategies. 3D printing is compatible with a wide range of lightweight materials, so aerospace companies can manufacture lighter components. This practice, often called “lightweighting,” translates to greater fuel efficiency and aircraft range, both of which are valuable in the aerospace industry.
Customizable Tooling
3D printing in aviation has tooling benefits as well. 3D printing allows aircraft manufacturers to build custom tooling faster and often at a lower cost, making highly customized parts – and greater innovation – more accessible.
Consolidation of Parts
Utilizing 3D printing in the aerospace industry allows for the consolidation of multiple components during the aircraft manufacturing process. By 3D printing multiple connected parts at once, aerospace companies can reduce the time and costs associated with complex assemblies.
Benefits of 3D Printing in Aerospace
The benefits of aerospace 3D printing range from waste reduction to greater innovation, leading to reduced costs and greater efficiency.
Reduced Material Waste
3D printing and other aerospace additive manufacturing techniques produce far less scrap material than some traditional methods. Integrating 3D printing into the aerospace industry allows aircraft manufacturers to cut down on waste and use materials more efficiently. This is especially valuable in the event of a material shortage and precious resources must be used judiciously.
Improved Design Flexibility
3D printing is an extremely flexible manufacturing process, offering nearly unlimited customization opportunities. 3D printing in aerospace gives aerospace manufacturers the flexibility to experiment with innovative designs of new and existing components, so they can continuously improve their aircraft and stay competitive in a fierce market.
Cost Savings
Aerospace companies can realize multiple avenues of cost savings when they opt for 3D printing. As previously mentioned, 3D printing uses material more efficiently and cuts down on scrap waste, reducing material costs. 3D printing also gives aircraft manufacturers the ability to build multiple components of an assembly at once, eliminating the costs associated with multiple assembly steps. Lastly, because 3D-printed parts can be lighter, airlines and other aircraft operators may realize savings on an operational level due to increased fuel efficiency.
Challenges and Future Developments
3D printing in aviation has tremendous potential for innovation and advancement. However, since this technology is still in its early stages, there are some current and future challenges to be aware of.
Material Limitation
For many aerospace components, material durability is a top consideration for performance and longevity. Unfortunately, certain materials simply are not compatible with 3D printing – at least not at this stage. The potential of 3D printing in aerospace is somewhat limited by the existing portfolio of materials that are both durable enough for aerospace applications and compatible with 3D printing.
Quality Control
3D printing is not immune to quality changes. Variability issues such as warping, porosity, and surface irregularities can occur, which is problematic for components with tight tolerances. Unfortunately, traditional quality control methods are not always sufficient for 3D-printed components. This is largely because the additive manufacturing process creates both material and geometry simultaneously, forcing manufacturers to essentially conduct two types of quality control at the same time. New quality control methods for 3D printing are in development, but aerospace companies must navigate this challenge creatively in the meantime.
Certifications
Industry standards and certifications are critical to ensuring uniformity and quality in any industry. Some regulatory bodies are more stringent than others about granting certifications. Because 3D printing is a newer addition to the aerospace manufacturing world, there are no existing certifications for this manufacturing method. Developing appropriate standards will take time, and some manufacturers may need to change their methods in order to earn these certifications once they are announced.
NMG Aerospace’s Commitment to Innovation
NMG has witnessed and supported decades of paradigm-shifting innovations in the aerospace industry. As a leading aerospace manufacturer, we are continuously investing time and resources into aerospace research and development. Mastering new innovations drives the future of aerospace manufacturing forward and supports our clients’ ambitious goals in this competitive industry.
From design support to U.S.-based manufacturing, NMG Aerospace is committed to supporting innovation at every stage of the aerospace component production process. To learn more about our services and capabilities, talk to a member of the NMG team.
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