Speed Of Printing 3D Metal Parts Improving
3D printing of polymer parts for aircraft interiors is quite old. But metal is not naturally a convenient liquid, and metal aircraft parts tend to be safety-critical, so printing metal parts has taken longer to advance.
Nevertheless, the pace of metal printing is picking up. It started with an OEM of engines, where weight and performance are critical. It is now spreading well beyond to a variety of components and structures.
OEMs are also diversifying their use of 3D technologies. Metal powders as well as wires are being used, and different techniques for printing metal materials are being exploited.
The two simplest appeals of printing have been cutting waste and producing parts quickly in small volumes. The first can cut costs, while the second speeds parts to market, eliminating the need for massive inventories.
But, 3D printing’s real potential is in redesigning whole systems and components to the exact configuration and content required for their functions, not designing a part or collection of parts just to ease manufacture by conventional methods. This potential will only truly be tapped as new engines and aircraft are developed.
So there is much more coming in additive manufacturing. Smart OEMs are taking early steps, partly for reasons specific to each printed piece, but also to gain experience for the future additive aerospace industry.
Honeywell Aerospace has already begun printing metal parts for its auxiliary power units (APU). Donald Godfrey, an engineering fellow in additive manufacturing at Honeywell, explains the change: If a component already is in use, then printing it replaces sheet-metal forming, welding, casting or forging.
One reason for printing a part might be that conventional manufacturing is not yielding timely production. Honeywell might also decide to print a part if the traditional supplier moved away or is no longer associated with the company. Or Honeywell might print a component if the vendor is having problems meeting quality standards.
