Manufacturing & Prototyping

3 Key Benefits: Better Corrosion Resistance, Fatigue Life, Part Integrity

Electropolishing has become a common metal finishing process used in the aerospace industry to help improve the overall quality of metal components. These components come in many forms including high-performance fasteners, fittings, nozzles, housings, and welded assemblies. In order to maintain reliable performance, these components must be precisely manufactured and have an impeccable surface finish that is free of burrs and other contaminants.

Posted in: News, News, Aeronautics, Aerospace, Aviation, Consumer Product Manufacturing, Custom & Contract Manufacturing, Manufacturing & Prototyping, Coatings & Adhesives, Materials, Metals, Joining & Assembly, Mechanical Components
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Recycled Water Bottles Could Help Avoid Military Supply Snags

Soldiers on the battlefield or at remote bases often have to wait weeks for vital replacement parts. Now scientists report they have found a way to fabricate many of these parts within hours under combat conditions using water bottles, cardboard and other recyclable materials found on base as starting materials for 3D printing. They say this ‘game-changing’ advance could improve operational readiness, reduce dependence on outside supply chains, and enhance safety.

“Ideally, soldiers wouldn’t have to wait for the next supply truck to receive vital equipment,” Nicole Zander, Ph.D., says. “Instead, they could basically go into the cafeteria, gather discarded water bottles, milk jugs, cardboard boxes and other recyclable items, then use those materials as feedstocks for 3D printers to make tools, parts and other gadgets.”

Posted in: News, Defense, 3 D Printing & Additive Manufacturing, Materials, Plastics
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Integrated Magneto-Optical Devices for On-Chip Photonic Systems

The magneto-optical (MO) oxide layer consists of (Bi,Y)3Fe5O12 or BiYIG, bismuth garnet. This material was selected because it has a better figure of merit than the CeYIG previously used, especially at lower wavelengths (1310 nm vs. 1550 nm). A top-down deposition process was developed in which BiYIG/YIG stacks are grown on the Si waveguide with YIG on top. The stack is annealed at 800°C/5 min to crystallize both layers, with the YIG templating the BiYIG leading to garnet phases rather than other oxides, and the BiYIG is directly on the Si waveguide. Initial attempts led to a film with Bi oxide phases, because the Bi was in excess and could not escape during the anneal as occurs in Si/YIG/BiYIG stacks. Hence the composition was adjusted to include slightly more Fe, which yielded films with only garnet peaks.

Posted in: Briefs, Aeronautics, Aerospace, Aviation, Electronic Components, Electronics, Electronics & Computers, Manufacturing & Prototyping, Materials, Optical Components, Optics, Photonics, Semiconductors & ICs
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Using Thermoplastics in Aerospace Applications

In August 2017, Qantas Airlines laid down the challenge to both Boeing and Airbus to offer an aircraft that can cross one of aviation's “last frontiers.” That “last frontier” was an aircraft capable of flying an economical passenger load non-stop for over 20 hours. This would allow Qantas to offer direct service from Sydney to London or New York. Weight reduction through the use of thermoplastics and other technologies would be the key to any chance of success in this endeavor.

Posted in: Articles, Aeronautics, Aerospace, Aviation, Thermal Management, Manufacturing & Prototyping, Composites, Materials, Metals, Plastics, Data Acquisition, Sensors
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Hydraulic Testing of Polymer Matrix Composite 102mm Tube Section

The objective of this research was to hydraulically pressurize the internal diameter of one 102mm Polymer Matrix Composite (PMC) over-wrapped cylinder up to 25,000 pounds per square inch (psi) and during pressurization, in real time, collect and store pressure and strain data simultaneously. Strain data must be captured from the inside diameter of the oil filled metallic cylinder and from the outside diameter of the composite over-wrap material.

Posted in: Briefs, Aerospace, Data Acquisition, Electronic Components, Electronics, Electronics & Computers, Manufacturing & Prototyping, Composites, Materials, Metals, Joining & Assembly, Mechanical Components, Inspection Equipment, Instrumentation, Measuring Instruments, Monitoring, Test & Measurement
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3D Printed Spacecraft Parts

Stratasys Ltd.
Eden Prairie, MN
952-937-3000
www.stratasys.com/aerospace
Phoenix Analysis and Design
Technologies (PADT) Tempe, AZ
1-800-293-PADT
www.padtinc.com

Stratasys Ltd., a company that specializes in applied additive technology solutions, and Phoenix Analysis & Design Technologies, Inc. (PADT) have teamed up with Lockheed Martin Space to deliver next-generation 3D printed parts for NASA's Orion deep-space spacecraft. Key to the project are Stratasys advanced materials – including an ESD variant of the new Antero™ 800NA, a PEKK-based thermoplastic offering high performance mechanical, chemical, and thermal properties.

Posted in: Application Briefs, Aerospace, Defense, Thermal Management, 3 D Printing & Additive Manufacturing, Manufacturing & Prototyping, Materials, Plastics
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Diesel Frigate Engines

Fairbanks Morse
Beloit, WI
1-800-356-6955
www.fairbanksmorse.com

Fairbanks Morse - an EnPro Industries company - has been awarded a contract to deliver eight FM | Colt-Pielstick diesel engines to power four frigates for the Royal Saudi Navy. The purchase is a part of the Saudi Naval Expansion Program II which has been in the works for over a decade with a cost of about $20 billion.

Posted in: Application Briefs, Defense, Manufacturing & Prototyping, Power Transmission
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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.

Posted in: INSIDER, 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.

Posted in: INSIDER, News, Defense, 3 D Printing & Additive Manufacturing, Rapid Prototyping & Tooling
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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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