Manufacturing & Prototyping

Researchers Push Limits in High-Temp, Polymer Additive Manufacturing

Researchers at the Air Force Research Laboratory’s Materials and Manufacturing Directorate are “turning up the heat” in the field of polymer additive manufacturing. In conjunction with researchers at NASA’s Glenn Research Center and the University of Louisville, the team successfully printed the highest-temperature capable, reinforced polymer composite parts using additive manufacturing. Consisting of a high temperature thermoset resin infused with carbon fiber filaments, this state-of-the art material breakthrough sets the stage for next generation, cost-efficient Air Force manufacturing needs.

“This is an extremely impactful breakthrough in composite material additive manufacturing,” said Dr. Hilmar Koerner, a scientist on the Polymer Matrix Composite Materials and Processing Research Team and the driving force behind the novel discovery. “These 3-D printed parts can withstand temperatures greater than 300 degrees Celsius, making them potentially useful for turbine engine replacement parts or in hot areas around engine exhaust.”

Posted in: News, Aerospace, Defense, 3 D Printing & Additive Manufacturing, Composites, Materials, Plastics
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Laser-Made Parts Could Transform Aircraft Industry

Researchers are manufacturing steel and titanium aircraft parts using laser metal deposition technology. It can be used to 3D-print parts from scratch or to fix existing parts with a bond that is as strong as, or in some cases, stronger than the original.

The technology could completely transform the concept of warehousing and transporting for defense and other industries. Instead of waiting for spare parts to arrive from a warehouse, an effective solution will now be on-site.

Source

Posted in: News, Defense, 3 D Printing & Additive Manufacturing, Rapid Prototyping & Tooling
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Streamlining Machinery and Production Lines With HP Multi Jet Fusion 3d Printing

Machinery and production line component production has typically been served with traditional processes such as CNC machining and injection molding. However, as industries strive to find greater efficiencies and add more value for their customers, machinery and production line manufacturers and runners are looking for ways to enhance and optimize how they produce components–in order to offer unique/customized solutions at low cost to their internal or external customers, drive greater production line efficiencies with lightweight, high performance parts, and maximize equipment uptime. 3D printing opens up a world of new opportunities for machinery and production line component production–both for original and spare parts.

Posted in: White Papers, White Papers, White Papers, Aeronautics, Manufacturing & Prototyping, Robotics
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Automated Process Prints Aircraft Parts

Copper cables run through the fuselage of aircrafts. They transmit electrical signals for temperature-measuring sensors, LEDs in ceilings, or electronic connections in seats. During their installation, individual cables are combined into harnesses. A new manufacturing process eliminates the classic laying of the cable harnesses, saving space and weight.

Posted in: News, Aerospace, Defense, 3 D Printing & Additive Manufacturing, Manufacturing & Prototyping
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Meeting Environmental Objectives and Regulations

Gone are the days when the impact of products on the environment or human health were optional business concerns. Regulatory constraints on materials and chemicals are increasing, and many companies struggle to respond – and to do so quickly and efficiently. Restrictions on hexavalent chrome are one well-known example. Another is REACH – the European Union regulation concerning the Registration, Evaluation, Authorisation & restriction of Chemicals – which applies to products that are either manufactured in, or imported into, the EU. Companies are under obligations to report the use of restricted substances, and to limit or avoid their use.

Posted in: Articles, Aerospace, Government, Environmental Monitoring, Manufacturing & Prototyping, Coatings & Adhesives, Materials, Data Acquisition, Computer-Aided Design (CAD)
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Using the Full CAD-CAM-CNC Process Chain in Ultrasonic and Conventional 5-Axis Machining

DMG MORI manufactures a wide variety of conventional chip-cutting and ultrasonic machining centers for OEMs and production job shops serving the aerospace industry. Inherent in this industry are several factors that require great care and planning in the machining process.

Posted in: Articles, Manufacturing & Prototyping, Machinery, Simulation Software
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How Additive Manufacturing is Changing the Aerospace Industry

Additive manufacturing was invented more than 30 years ago and, from small beginnings in prototyping, has developed and grown into a $6 billion industry. While additive manufacturing for aerospace and defense has seen slower adoption than some other industries, the velocity is now visibly increasing. This has been enabled by the ongoing development of additive technologies that apply more increasingly to aerospace and defense -namely better plastics materials, faster 3D printing technologies, focused development of metals materials, and resulting technologies and processes that are increasingly easier to get qualified.

Posted in: Articles, Aerospace, 3 D Printing & Additive Manufacturing, Manufacturing & Prototyping, Rapid Prototyping & Tooling, Materials, Metals
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CAM Software Technology Keeps Pace with Aerospace Manufacturing Challenges

Aerospace industry component manufacturing is in a large growth cycle. Advancements to materials and engine efficiency have created clear benefits for replacing a surplus of older aircraft equipment. The advancements cover both engine and structural components. The demand is so significant that machine tool makers are challenged to supply equipment fast enough.

Posted in: Articles, Aeronautics, Aerospace, Aviation, Manufacturing & Prototyping, Machinery, Mechanical Components, Computer-Aided Design (CAD), Computer-Aided Manufacturing (CAM), Software
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First Air-Worthy Metal-Printed RF Filter Ready for Takeoff

Within the aerospace industry, 2016 and onwards could be looked upon as the tipping point for direct metal printing (DMP), as the technology increasingly made the jump beyond prototyping to production parts and assemblies ready for flight.

Posted in: Articles, Aerospace, Communications, 3 D Printing & Additive Manufacturing, Manufacturing & Prototyping, Materials, Metals, RF & Microwave Electronics
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Designing With Plastics for Military Equipment

U.S. soldiers carry loads of equipment and protective gear that can weigh anywhere from 45 to 130 pounds. This is more than enough to quickly tire even the most well-conditioned personnel, contributing to reduced mobility and impaired decision-making that could result in casualties.

Posted in: Articles, Aerospace, Defense, Manufacturing & Prototyping, Composites, Materials, Metals, Plastics
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