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US$4 million to improve AM aerospace repair
additive manufacturing US$4 million to improve AM aerospace repair
Optomec is tasked with improving additive manufacturing (AM) technology in the repair of aerospace metal components for the US Air Force.
3D printing specialist Optomec has been awarded a major project from America Makes (the National Additive Manufacturing Innovation Institute) to improve additive manufacturing (AM) technology to repair aerospace metal components for the US Air Force. The ‘Re-Born in the USA’ project will use the company’s LENS 3D metal printing to develop a reliable, cost-effective approach to replace conventional repair
processes such as manual welding. This includes definition of optimum powder feedstock characteristics, improvements in process monitoring and control, and recommendations for part repair and sustainment applications specifically for the Air Force.The potential benefits of using additive manufacturing to repair high value metal components include lower costs, higher quality, longer life, and faster return to service.
Optomec will lead a project team consisting of 23 partners, including aerospace industry leaders GE Aviation, Lockheed Martin, United Technologies Research Center, and RollsRoyce, as well as a group of technical experts serving as lead contributors including EWI, Connecticut Center for Advanced Technology, TechSolve, the Pennsylvania State University Applied Research Lab, and Concurrent Technologies Corporation. Unlike some powder bed additive manufacturing approaches, the LENS process can add metal onto an existing substrate of almost any three-dimensional shape. Powder-bed processes require a flat, two-dimensional horizontal base. This makes the LENS Additive Manufacturing process qualified to perform repair operations. LENS machines are already in use conducting repairs of ground based high value compo-
nents for defence and other industries. AM application “This award is significant because it highlights that repair is indeed a leading application area in the additive manufacturing landscape,” said Dr Richard Grylls, Optomec LENS general manager and project leader. “We are looking forward to working with our partners to deliver a repair methodology that addresses the current challenges faced by the Air Force and provides a framework for the potential adoption of additive manufacturing repair processes throughout the aircraft industry. Together, we will demonstrate the benefits of additive manufacturing over traditional welding techniques and enable a ‘repair, don’t replace’ approach to critical part sustainment for high-value aerospace components.” This is the third America Makes project awarded to Optomec this year.
3D tool maker uses improved metal powders Toolcraft, a manufacturer of precision metal parts and components, is using metal powders sourced from LPW Technology to make its 3D printed parts. Toolcraft makes micro-components with high dimensional accuracy for a wide range of industries includingbiomedical, defence and motorsport. Many of the company’s customers are in the medical technology and aerospace sectors, which require the use of certified materials. For applications in these industries, a secure
metal-powder.net
supply of certified powders and the ability to produce components to extremely precise specifications are important. “LPW are ahead of other suppliers in terms of the way in which they analyse powders under the conditions needed to provide relevant data for AM,” said Christoph Hauck, MD of Toolcraft. “They also understand how to use these data to help us identify an optimised powder for a specific AM application.” Besides the metal powders, LPW Technology
is also delivering application support and analytical
information to help manufacture.
Toolcraft makes micro-components with high dimensional accuracy for a wide range of industries including motor sport.
September/October 2014 MPR
43
Optomec is tasked with improving additive manufacturing (AM) technology in the repair of aerospace metal components for the US Air Force.
3D printing specialist Optomec has been awarded a major project from America Makes (the National Additive Manufacturing Innovation Institute) to improve additive manufacturing (AM) technology to repair aerospace metal components for the US Air Force. The ‘Re-Born in the USA’ project will use the company’s LENS 3D metal printing to develop a reliable, cost-effective approach to replace conventional repair
processes such as manual welding. This includes definition of optimum powder feedstock characteristics, improvements in process monitoring and control, and recommendations for part repair and sustainment applications specifically for the Air Force.The potential benefits of using additive manufacturing to repair high value metal components include lower costs, higher quality, longer life, and faster return to service.
Optomec will lead a project team consisting of 23 partners, including aerospace industry leaders GE Aviation, Lockheed Martin, United Technologies Research Center, and RollsRoyce, as well as a group of technical experts serving as lead contributors including EWI, Connecticut Center for Advanced Technology, TechSolve, the Pennsylvania State University Applied Research Lab, and Concurrent Technologies Corporation. Unlike some powder bed additive manufacturing approaches, the LENS process can add metal onto an existing substrate of almost any three-dimensional shape. Powder-bed processes require a flat, two-dimensional horizontal base. This makes the LENS Additive Manufacturing process qualified to perform repair operations. LENS machines are already in use conducting repairs of ground based high value compo-
nents for defence and other industries. AM application “This award is significant because it highlights that repair is indeed a leading application area in the additive manufacturing landscape,” said Dr Richard Grylls, Optomec LENS general manager and project leader. “We are looking forward to working with our partners to deliver a repair methodology that addresses the current challenges faced by the Air Force and provides a framework for the potential adoption of additive manufacturing repair processes throughout the aircraft industry. Together, we will demonstrate the benefits of additive manufacturing over traditional welding techniques and enable a ‘repair, don’t replace’ approach to critical part sustainment for high-value aerospace components.” This is the third America Makes project awarded to Optomec this year.
3D tool maker uses improved metal powders Toolcraft, a manufacturer of precision metal parts and components, is using metal powders sourced from LPW Technology to make its 3D printed parts. Toolcraft makes micro-components with high dimensional accuracy for a wide range of industries includingbiomedical, defence and motorsport. Many of the company’s customers are in the medical technology and aerospace sectors, which require the use of certified materials. For applications in these industries, a secure
metal-powder.net
supply of certified powders and the ability to produce components to extremely precise specifications are important. “LPW are ahead of other suppliers in terms of the way in which they analyse powders under the conditions needed to provide relevant data for AM,” said Christoph Hauck, MD of Toolcraft. “They also understand how to use these data to help us identify an optimised powder for a specific AM application.” Besides the metal powders, LPW Technology
is also delivering application support and analytical
information to help manufacture.
Toolcraft makes micro-components with high dimensional accuracy for a wide range of industries including motor sport.
September/October 2014 MPR
43