German multinational engineering group Thyssenkrupp has obtained certification for its supply of metal 3D printed products. The company’s Approval of Manufacturer certificate is the first ever to be awarded by leading quality assurance and risk management firm DNV GL. With the accreditation, the recently opened Thyssenkrupp TechCenter Additive Manufacturing is now approved for application in maritime and other industrial sectors.
“Producing components that have the same level of quality as conventionally manufactured parts and fulfil class requirements is key,” comments Geir Dugstad, Director of Ship Classification & Technical Director of DNV GL – Maritime, “At DNV GL, we are very pleased to certify that the Thyssenkrupp TechCenter Additive Manufacturing has demonstrated its ability to reliably produce metallic materials using additive manufacturing,”
Formula One (F1), the premier world championship for motor racing and its governing body the Fédération Internationale de l’Automobile (FIA), have used additive manufacturing to help determine the design, rules and regulations of its 2021 cars.
Each F1 season, the FIA issues new regulations for vehicles participating in the championship. The new rules are tested using prototype car models implemented. Last month, the 2021 vehicle underwent extensive wind tunnel testing using an accurate, 50 percent scale model produced with the help of additive manufacturing.
The wind tunnel tests were performed by an independent consultancy group from Sauber, a Swiss motorsport engineering company, using its own wind tunnel facility. The use of additive manufacturing to create the scale models delivered a number of benefits to the development team. Pat Symonds, F1’s Chief Technical Officer, stated “50% is a good compromise in that we can still get a good level of detail on the model but we still have distance behind. It’s true teams have tended to go more to 60% these days.”
Access to and use of additive manufacturing (AM), also known as 3D printing, has increased in recent years due to the expiring of patents on techniques and technologies, says Hugues Greder, Lead Petroleum Engineer at Total.
Computing power is much more powerful and there’s also been an increase in the power of the lasers used in the AM process. While a large proportion of AM today is still for prototyping and tooling, about a third is for end uses, i.e. parts, he told the Underwater Technology Conference (UTC) in Bergen, Norway, earlier this year. And more is likely to come.
Total is keen to talk about AM after some recent success stories, including solving a problem during deepwater subsea pipeline commissioning that would have otherwise cost more than €10 million ($11.2 million) to rectify. The problem was found during the Egina field commissioning in 2018.
3 D Printing is in its infancy in terms of providing parts for the military.
A challenge for the military is of course the need for parts reliability and ruggedness at very high standards.
This is why the term “military grade” was invented.
But as 3D printing becomes part of the sustainment enterprise, there are very significant impacts to be anticipated.
“Just in time” gets a whole new meaning when one can build parts locally.
This means as well that distribute operations can be facilitated more effectively.
And there is a significant potential reduction on the supply fleet, whether it be by land, sea or air.
3D printing (additive manufacturing) is revolutionizing the very concept of manufacturing across just about every industry. But some of the most mind-blowing advances are taking place in the medical world.
How Is 3D Printing Used in Health Care?
Perhaps the least surprising – but most practical – use of 3D printers in the medical profession is the printing of medical equipment and instrumentation. Aid groups in Haiti, for example, have printed umbilical cord clamps and other medical devices to make up for supply shortages and affordability issues. Other instruments might include guides to assist with the proper surgical placement of a device.
3D-printed implants have the potential to replace damaged or worn body parts as easily as a mechanic replaces the parts of a vehicle’s engine. Already, plastic or titanium implants such as cranial plates or hip joints are being printed and put to use.
As additive manufacturing goes mainstream, supply chains are presented with tough decisions. Are the speed and flexibility worth the cost?
To produce brake calipers for its Chiron supercar, Bugatti embraced additive manufacturing, creating the largest titanium 3D printed component yet.
Because titanium is so strong, it’s impossible to use the same milling and forging technology used to form traditional aluminum calipers, Popular Science reported. Instead, the part is produced from 2,213 layers of titanium powder melted by lasers for over 45 hours and then heat-treated to 1,300 degrees. The part undergoes 11 hours of grinding to ensure each component meets exacting tolerances.
Unattended, low-volume production of functioning circuitry is now an option
It’s been a year of firsts for electronics 3D printing, with the launch of Lights-Out Digital Manufacturing (LDM), a manufacturing technology in which systems run with little or no human intervention around the clock. Here’s a quick look at LDM technology and the development of a variety of innovative 3D printed applications for printed electronics.
3D printing is transforming the way we design and manufacture electronics. It overcomes constraints in traditional approaches to the printed circuit board (PCB) and electronics production, regarding speed, complex workflows and resources. New designs can be quickly run through a more efficient in-house manufacturing process, providing faster execution of design, build, and test cycles.
This is enabling manufacturers to push boundaries, drive innovation and get to market faster than their competitors. However, with the coming digital manufacturing revolution, automation is increasingly pursued to extend the capabilities of additive manufacturing from rapid prototyping to low-volume, short-run manufacturing. The main goal is to increase factory output, reduce operational costs and produce unique functional electronic circuitry that is impossible to make with any other method.
It lets aerospace engineers develop high-quality parts much faster than they could with traditional fabrication methods
July 2019 marked the 50-year anniversary of the Apollo 11 moon landing. While the world has seen incredible technological and scientific strides since then, the broader space industry has been in stealth mode—exploring what’s possible, and what’s next, for humankind in space.
In 2018, the space sector grew to an incredible $3.25 billion industry. A number of different technologies are driving this rapid growth, but the most promising one is industrial-grade 3D metal printing (a.k.a. metal additive manufacturing). Once met with skepticism, 3D metal printing has proven itself to be a cost-effective and efficient way to develop production-ready parts, making it the new darling of the commercial race to space.
The U.S. Air Force announced its first use of certified replacement aircraft parts made by a 3D industrial printer on Monday.
The 60th Maintenance Squadron at Travis AFB, Calif., is the Air Force’s first field unit with an industrial-sized 3D printer certified to produce nonstructural aircraft parts.
The Stratasys F900 3D printer is capable of printing plastic parts up to 36-by-24-by-36 inches, using Ultem 9085, a flame-retardant high-performance thermoplastic regarded as more flexible, dense and stronger than typical plastic.
The printer, certified by the Federal Aviation Administration and the Air Force Advanced Technology and Training Center, offers new opportunities to create needed parts while saving time and money, an Air Force statement said on Monday.
Award-winning OEM GE Additive has signed a Memorandum of Understanding (MoU) with the New South Wales (NSW) Government in Australia to develop a 3D printing aerospace centre at the Western Sydney Aerotropolis.
Following a visit to the GE Additive Customer Experience Centre in Munich, NSW premier Gladys Berejiklian said, “3D printing is on the cutting edge of manufacturing globally and this deal will help make Western Sydney the nation’s leader.”
“Our partnership with GE Additive will create many hi-tech jobs across the aerospace, medical and automotive sectors.”