- Email: [email protected]
EADS says AM can cut material consumption and CO2 emissions
Scientists 3D print titanium horseshoe for racehorse
Traditionally made from aluminium, a horseshoe can weigh up to one kilogram.
Scientists from the Commonwealth Scientific and Industrial Research Organisation (CSIRO) have 3D printed a bespoke set of titanium shoes for a Melbourne racehorse. The horse had its hooves scanned with a handheld 3D scanner, and using 3D modelling software the scan was used to design four perfect fitting, lightweight racing shoes within only a few hours. Traditionally made from aluminium, a horseshoe can weigh up to one kilogram; but the horse’s trainer, John Moloney, says that the ultimate race shoe should be as lightweight as possible. “Any extra weight in the horseshoe will slow the horse down,” he explained. “These titanium shoes could take up to half of the weight off a traditional aluminium shoe, which means a horse
42
could travel at new speeds. Naturally, we’re very excited at the prospect of improved performance from these shoes.” CSIRO’s titanium expert, John Barnes, said that 3D printing a race horseshoe from titanium is a first for scientists and demonstrates the range of applications for which the technology can be used. “There are so many ways we can use 3D titanium printing,” Barnes said. “At CSIRO we are helping companies create new applications, such as biomedical implants and even things like automotive and aerospace parts. The possibilities really are endless with this technology.” The precision scanning process takes just a few minutes; for a horse, shoes can be made to measure each hoof and printed the same day.
MPR November/December 2013
EADS says AM can cut material consumption and CO2 emissions In recent tests by EADS’ research and technology organisation Innovation Works (IW), EOS’s direct metal laser-sintering (DMLS) process was tested with positive results. The process is being used by EADS IW to manufacture demonstration parts to explore improved design and production sustainability. The results from the initial joint study of AM were evaluated in terms of CO2 emissions, energy and raw material efficiency and recycling. When analysing energy consumption, the company’s investigation included not only the production phase, but also the sourcing and transportation of raw materials, argon consumption for the atomisation of the DMLS metal powder, and overall waste from atomisation. In the test, cast steel nacelle hinge brackets were compared to an additively manufactured (AM) bracket of optimised titanium design by measuring the energy consumption over the whole life cycle. For this application the operational phase is typically 100 times more
important than the static phases (manufacturing the part). A comparison was made between manufacturing the optimised titanium component by rapid investment casting and on an EOS platform. Energy consumption for the life cycle of the bracket, including raw material manufacture, the production process and the end-of-life phase, is slightly smaller on the EOS platform compared with rapid investment casting. The main advantage of the EOS technology, however, is that the additive process uses only the amount of material for manufacture that is in the product itself. Thus consumption of raw material can be reduced by up to 75%. The study focused on the comparison between DMLS and rapid investment casting of a single part and did not take into account the question of scalability. The design of the nacelle hinge bracket also allowed EADS and EOS to demonstrate the potential to reduce the weight per aircraft by approximately 10 kg.
Graphene 3D project approved American Graphite Technologies Inc has received final approval from the Science and Technology Centre Ukraine (STCU) for the start-up of its P600 project, researching the use of nanocarbon-contained matter for 3D printing. P600 is a collaboration between American Graphite and the Kharkov Institute of Physics and Technology in Kharkov, Ukraine. It will
research materials containing nanostructured carbon, primarily graphene, and existing and prospective methods of 3D printing, to create 3D objects using nanocarbon material. The project team will consist of eight scientists and PhDs with experience in the fields of nanotechnology, 3D printing, solid state physics, physical materials and thermal physics.
metal-powder.net
Traditionally made from aluminium, a horseshoe can weigh up to one kilogram.
Scientists from the Commonwealth Scientific and Industrial Research Organisation (CSIRO) have 3D printed a bespoke set of titanium shoes for a Melbourne racehorse. The horse had its hooves scanned with a handheld 3D scanner, and using 3D modelling software the scan was used to design four perfect fitting, lightweight racing shoes within only a few hours. Traditionally made from aluminium, a horseshoe can weigh up to one kilogram; but the horse’s trainer, John Moloney, says that the ultimate race shoe should be as lightweight as possible. “Any extra weight in the horseshoe will slow the horse down,” he explained. “These titanium shoes could take up to half of the weight off a traditional aluminium shoe, which means a horse
42
could travel at new speeds. Naturally, we’re very excited at the prospect of improved performance from these shoes.” CSIRO’s titanium expert, John Barnes, said that 3D printing a race horseshoe from titanium is a first for scientists and demonstrates the range of applications for which the technology can be used. “There are so many ways we can use 3D titanium printing,” Barnes said. “At CSIRO we are helping companies create new applications, such as biomedical implants and even things like automotive and aerospace parts. The possibilities really are endless with this technology.” The precision scanning process takes just a few minutes; for a horse, shoes can be made to measure each hoof and printed the same day.
MPR November/December 2013
EADS says AM can cut material consumption and CO2 emissions In recent tests by EADS’ research and technology organisation Innovation Works (IW), EOS’s direct metal laser-sintering (DMLS) process was tested with positive results. The process is being used by EADS IW to manufacture demonstration parts to explore improved design and production sustainability. The results from the initial joint study of AM were evaluated in terms of CO2 emissions, energy and raw material efficiency and recycling. When analysing energy consumption, the company’s investigation included not only the production phase, but also the sourcing and transportation of raw materials, argon consumption for the atomisation of the DMLS metal powder, and overall waste from atomisation. In the test, cast steel nacelle hinge brackets were compared to an additively manufactured (AM) bracket of optimised titanium design by measuring the energy consumption over the whole life cycle. For this application the operational phase is typically 100 times more
important than the static phases (manufacturing the part). A comparison was made between manufacturing the optimised titanium component by rapid investment casting and on an EOS platform. Energy consumption for the life cycle of the bracket, including raw material manufacture, the production process and the end-of-life phase, is slightly smaller on the EOS platform compared with rapid investment casting. The main advantage of the EOS technology, however, is that the additive process uses only the amount of material for manufacture that is in the product itself. Thus consumption of raw material can be reduced by up to 75%. The study focused on the comparison between DMLS and rapid investment casting of a single part and did not take into account the question of scalability. The design of the nacelle hinge bracket also allowed EADS and EOS to demonstrate the potential to reduce the weight per aircraft by approximately 10 kg.
Graphene 3D project approved American Graphite Technologies Inc has received final approval from the Science and Technology Centre Ukraine (STCU) for the start-up of its P600 project, researching the use of nanocarbon-contained matter for 3D printing. P600 is a collaboration between American Graphite and the Kharkov Institute of Physics and Technology in Kharkov, Ukraine. It will
research materials containing nanostructured carbon, primarily graphene, and existing and prospective methods of 3D printing, to create 3D objects using nanocarbon material. The project team will consist of eight scientists and PhDs with experience in the fields of nanotechnology, 3D printing, solid state physics, physical materials and thermal physics.
metal-powder.net