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DMLS Warheads

By i3d

New Case Studies: Additive Manufacturing (DMLS) Optimization Warheads And Aircraft Wings

We have added two new case studies to our DMLS Resource Library.  Major David Liu and others at the Airforce Institute of Technology (AFIT) have published groundbreaking studies based on Additive Manufacturing (DMLS) optimization of aircraft wings and lattice-reinforced penetrative warheads.

Topology Optimization Of An Aircraft Wing

For the additive manufacturing industry and specifically DMLS aircraft printing, this is a very important study.  Here’s the summary from the white paper which can be found here in our library:

Topology optimization was conducted on a three-dimensional wing body in order to enhance structural performance and reduce overall weight of the wing. The optimization was conducted using commercial software on an aircraft wing with readily available schematics, allowing a stress and displacement analysis. Optimizations were accomplished with an objective of minimizing overall compliance while maintaining an overall design-space volume fraction of less than 30 percent. A complete wing segment was post processed and 3D printed. Future analysis involves the optimization of a complete wing body with comparison to the baseline structure. The resulting designs will be 3D printed and wind-tunnel tested for process verification. A design will also be manufactured using metallic additive manufacturing techniques as a proof of concept for future aircraft design. The final optimized solution is expected to provide a weight savings between 15 and 25 percent.

 

Topology Optimization of Additively-Manufactured, Lattice-Reinforced Penetrative Warheads

A second case study along with a great presentation by Captain Hayden K. Richards and Major David Liu discusses the groundbreaking effect of DMLS on lattice-reinforced warheads. Penetrative warheads, characterized by massive, strong, and tough solid cylindrical cases with ogive noses, are generally manufactured using traditional techniques such as subtractive fabrication processes. In these processes, material is removed from pre-formed solid masses to produce simple shapes.

Recently, the development of sophisticated additive manufacturing (AM) machines, known colloquially as 3D printers, has revolutionized the process of building metal parts.

Visit our library for access to these incredible studies which help to reinforce the growing use of DMLS in critical industries such as aerospace and firearms.

By i3d

I3DMFG DMLS Resource Library

Introducing Our DMLS Resource Library

I3D MFG™ has put together an online DMLS resource library for anyone that wants to learn more about the industry, materials used, and actual case studies of DMLS in action.  Here is what you will find in our library.

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i3DMFG-3D-Printing-Services-Aerospace

By i3d

3D Printed Rocket Parts? Yes!

Are companies successfully making 3D printed rocket parts?  As the 3D metal printing industry continues to mature using technologies like Direct Metal Laser Sintering (DMLS) for bridge manufacturing using metals such as Inconel and Titanium, there has been an uptick in the number of successful 3D printed rocket parts.

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By Erin Stone

Can 3D Metal Printed Rocket Parts Hold Up To Stress Tests?

As part of it’s AR1 booster engine project, Aeroject Rocketdyne put some 3D printed rocket parts under fire. The parts were subjected to a round of hot-fire tests in preparation for an AR1 engine production by 2019.  Can 3D Printed parts hold up to such strenuous and exhaustive testing?

A little background.  Aerojet Rocketdyne is currently developing the AR1 for full production.  The AR1 is a 500,000 lb thrust-class liquid oxygen/kerosene booster engine which is an American-made alternative to the likes of the Russian built RD-180.   Aerojet is preparing for the replacement of the RD-180 due to a new rule from the National Defense Authorization Act which was enacted in 2015 that calls for the replacement of the RD-180 for “national security space launches by 2019.”

Due to the function of a booster engine, these types of tests come at an important time for 3D metal printed parts.  The industry is experiencing significant growth in the use of Inconel and Titanium metal powder printing which has yielded incredible results in not only the aerospace industry but in the firearms and medical industries as well.

In order to bring the AR1 to market by 2019, testing has to begin now and it’s an incredible amount of heat and stress they are placing these 3D metal printed parts under. The motivation for these hot-fire tests was an evaluation of various main injector element designs and fabrication methods.

A few of the injectors were fabricated using Selective Laster Melting (SLM) and Aerojet has invested heavily into the use of SLM capabilities for rocket engine applications.

Aerojet Rocketdyne fully believes that the AR1 single-element hot-fire tests are the highest pressure hot-fire tests (over 2,000 psi) of a 3D metal printed part in rocket engine application.  Because of the success of these tests, Aerojet Rocketdyne says that 3D metal printing will account for a potential 70% reduction in cost for production of the main injector, and a possible nine-month reduction in part lead times.

So. Can 3D metal printed rocket parts hold up to extreme stress testing? Yes!  And this is just the beginning of an upward trend as 3D metal printing using Inconel, Titanium, and Maraging Steel see massive success in other large industries such as firearms and medical.  Stay tuned for your next 3D printed car….

Inserts and Complex Lattice Geometries

By i3d

3D Printing Survey Points To Strong Demand For Investors

There continues to be strong demand for the 3D printing and additive manufacturing industry, as pointed out in a recent report from market research leaders PiperJaffray. The research included 79 industry respondents and revealed why they feel bullish on 3D printing and additive manufacturing as a continued growth market for investors.

Here are some of the results of the research which clearly shows that 3D printing and additive manufacturing is a growth industry for investors and also an increasing entry point for new resellers.

Reseller Composition

Over the past year there has been a sizable increase in the number of resellers that have been operating in the 3D printing/additive manufacturing space for less than five years.  This shows a strong growing demand for 3D printing and related service delivery.  A lot of this demand and growth comes from new respondents to the research which reveals they are Stsratasys (SSYS) resellers.  Stratasys is seeing massive growth in the number of people reselling their 3D printing/additive manufacturing equipment and that has a direct correlation to the growing demand for the related services.

Other resellers such as EOS also reported growth, however, they tend to take a more direct approach without relying too heavily on resellers.

In the attached report (PDF), PiperJaffray outlines all of the detailed market signals which point to their bullish recommendation for investors looking at the 3D printing industry.

Service Data Points To Strong 2015

New customers needing 3D printing/additive manufacturing services tend to utilize service providers instead of investing in their own equipment and this trend will persist for the foreseeable future as more and more companies leverage the technology.

In Q4, total growth expectations increased 4 percentage points to 17% which represents a slight uptick from Q3, believed to be due to companies seeing the cost and manufacturing benefits of 3D printing.

Final Thoughts

Due to the increasing reseller demand for 3D printing systems from manufacturers, more companies leveraging 3D printing, better throughputs, better materials and quicker-to-market finish times, market research leaders PiperJaffray feel that the 3D printing/additive manufacturing industry is bullish for investors.  Read the full PiperJaffray report, “Q4 3D Printing Survey Points To Strong System Demand From SSYS Resellers” for the detailed analysis, data gathered, and respondent feedback.

By Erin Stone

DMLS Stands Out as 2015 Focal 3D Printing Technology

DMLS Stands Out as 2015 Focal 3D Printing Technology

What makes Direct Metal Laser Sintering (DMLS) a leading 3D printing technology in 2015? It’s not new news that DMLS prints metal 3D parts. Here are some new exciting new trends  that Steve Heller, 3D specialist for the Motley Fool found “incredible”:

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Material Process Applications

By Erin Stone

Why 3D Printing is Predicted to Produce 50% of Parts & Components

3D Printing Predicted to Produce 50% of Parts & Components

A recently released Gartner study found that 3D printing is not only widely used for rapid prototyping and product development, but that ” it (3D printing) was starting to play a significant role in short run production of finished products.” What evidence does Gartner have to support that prediction? First, they performed a survey of 300 people from a multitude of 100+ employee organizations and 37% of them use end-use quality 3D parts.   Read more

By Erin Stone

3D Printing Takes the Cost of Complexity to Zero

3D Printing Takes the Cost of Complexity to Zero

Whats is the definition of “game changer” for metals manufacturing? Direct Metal Laser Sintering (DMLS), a 3D printing process that eliminates binding agents and uses 400-1000 W lasers to melt micro powders together, layer by layer until a 3D CAD model of a part is built, is one of the 3D manufacturing processes that are the the epitome of “game changer” according to Hod Lipson or Cornell University.   Read more

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DMLS Warheads
New Case Studies: Additive Manufacturing (DMLS) Optimization Warheads And Aircraft Wings
i3DMFG-3D-Printing-Services-Aerospace
3D Printed Rocket Parts? Yes!
Inserts and Complex Lattice Geometries
3D Printing Survey Points To Strong Demand For Investors
DMLS Stands Out as 2015 Focal 3D Printing Technology
Material Process Applications
Why 3D Printing is Predicted to Produce 50% of Parts & Components
3D Printing Takes the Cost of Complexity to Zero