July, 2022 | Supercharg3d

Construction 3D Printing study criticised: author responds with “challenges and opportunities”

Recent articles on 3D printing in construction have sparked a lively debate. Igniting that conversation was a paper on the potential benefits of concrete 3D printing. The co-author of that paper is Mustafa Batikha, an Assistant Professor at Heriot-Watt University.

Published last year, the study found that if a two-story structure built via precast concrete in the UAE had been 3D printed using a three-leaf printed cavity wall instead, the contractors’ material costs would’ve actually risen 44%.

This was due primarily to the expensive concrete needed for the build, as it was estimated that the proposed 3D printing method would be cheaper to carry out. Contrary to the often-cited eco-friendly benefits of the technology, the paper also showed that adopting it would only yield marginal sustainability gains.

First 3D printer installed on U.S. Navy ship for evaluation underway

The U.S. Navy recently installed its first 3D printer aboard one of its vessels in a program designed to test the capabilities of the technology and its potential contribution to enhancing maintenance aboard active duty vessels. The Navy joins with the commercial shipping industry which has also been looking at the capabilities of 3D printing and tested the first parts for ships made with the technology.

The 3D printing system was recently placed aboard the USS Essex, a Wasp-class Landing Helicopter Dock currently based at Pearl Harbor, Hawaii. Commissioned in 1992, the amphibious assault ship is testing the technology while it is currently participating in the Rim of the Pacific (RIMPAC) 2022 training exercise.

“Having this printer aboard will essentially accelerate, enhance, and increase our warfighting readiness,” said Lt. Cmdr. Nicolas Batista, the Aircraft Intermediate Maintenance Department (AIMD) officer aboard the Essex. “The capabilities of the 3D printer will enable Essex to become more self-sufficient.”

Bundeswehr is testing the production of spare parts on the frigate Sachsen

The Bundeswehr, which is repeatedly criticized for its poor state of equipment, is now providing spare parts on site as a test Frigate Saxony here. In a test lasting several days on the North Sea, it is to be checked whether machine and equipment parts produced by FDM printing can also be produced in sufficient quality under the special conditions of a warship.

Manufacturing parts using 3D printing, which is already routine in the automotive and railway industries as well as in aerospace (e.g. at Airbus), is much more difficult on ships because of the conditions prevailing there: the salt content of the air and the ship movements as well Vibrations from the drive often have a disruptive effect. On the other hand, using the ships, which are very powerful with more than 53,000 HP, is extremely expensive for the German Armed Forces. Aborting a mission and prematurely returning to the supply of spare parts due to a lack of spare parts would drastically increase this.

Heron Preston and Zellerfeld launch upgraded 3D printed Heron-1 Sneaker

Fashion designer Heron Preston and footwear 3D printing start-up Zellerfeld have released a new version of their co-designed 3D printed HERON01 sneaker, named Version 0.81.

The sneaker’s latest design and structure have reportedly been reimagined, with an improved collar shape, roomier toe box, and more lightweight feel due to reduced material usage.

Zellerfeld will be using the new version of the custom sneaker to update its footwear beta program in order to increase beta users’ access to its products.

London Borough of Hackney has high hopes for 3D printing technology in circular economy push

The London Borough of Hackney recently awarded £600,000 in grants via its Hackney Central Impact and Ideas Grant Fund, supporting local businesses pushing the circular economy.

The program involved a total of 23 green enterprises, including Batch.Works, an East London design and manufacturing studio using 3D printing to upcycle plastic waste into useful products. Riding off the back of the initiative, the Hackney Council is now actively encouraging other local businesses to partake in discussions regarding the circular economy, all in a bid to cut waste, reuse materials, and slash emissions.

Guy Nicholson, Deputy Mayor for Delivery, Inclusive Economy, and Regeneration, said, “It is all too easy to jettison some of our ambitions to reduce emissions, support the creation of a circular economy and play our collective part in transforming Hackney’s local economy and placing it at the forefront of the net zero carbon economy of tomorrow. Despite the challenges we face, the Council is determined to support the borough’s business owners to create the economy of tomorrow.”

AML3D to WAM 3D print colossal eight-tonne pressure vessel for ExxonMobil

Australian large-format 3D printer manufacturer AML3D has been contracted to build a massive eight-tonne pressure vessel by oil and gas multinational ExxonMobil.

Having received a $190,000 order from ExxonMobil, AML3D will now utilize its Wire Arc Manufacturing (WAM) facilities to produce the container, in a way that reduces its lead time from 12 months to just 12 weeks. As well as helping its client meet a tight delivery deadline of September 2022, AML3D says the project demonstrates 3D printing’s potential in an oil and gas sector where it’s increasingly gaining traction.

“Signing this deal with ExxonMobil is a further demonstration of delivery against our multi-phase growth strategy,” said Andrew Sales, MD of AML3D. “We have a major focus on building our capability and presence in the global oil and gas sector as an immediate value driver for the business and this contract absolutely aligns with that objective.”

Alstom and Replique aim for rolling stock series production with 3D printing technology

Alstom, a France-based rolling stock manufacturer, has begun using Replique’s on-demand 3D printing services for its industrial series production applications.

The firm has chosen to digitize a portion of its supply chain, citing manufacturing flexibility, shorter lead times, and lower costs as primary factors for the decision. With help from Replique, Alstom can produce small batches of metal components for its trains in a decentralized manner, enabling the firm to better address the local needs of clients worldwide.

Leveraging the recent partnership, Alstom has already received and installed its first set of visible 3D printed train parts: door stoppers made of stainless steel.