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3D Metal Printing – Future of Aerospace Engineering

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When fabricating aerospace components, it is essential to follow rigorous standards for safety and performance. Traditional manufacturing processes, such as casting and machining, have long been the backbone of the aerospace industry. However, these methods have limitations, especially at the forefront of creating complex, lightweight, and highly customized components. 3D metal printing, also known as additive manufacturing, has emerged as a game-changer for the aerospace fabrication industry. This innovative technology allows manufacturers to create three-dimensional objects by adding material layer-by-layer, rather than subtracting from a solid block. Let us examine the exciting potential 3D metal printing has for the future of aerospace manufacturing.

New Possibilities Unleashed

Here is a closer look at four ways 3D metal printing is propelling aerospace engineering into the future:

  • Complex Geometry: Aerospace components often require intricate designs to optimize their performance and efficiency. Traditional manufacturing methods, such as casting and machining, have limitations in producing complex shapes. 3D metal printing, on the other hand, excels at creating intricate geometries that were once deemed impossible or economically unviable.
  • Lightweight Structures: Weight reduction is a crucial factor in aerospace design. Lighter aircraft consume less fuel, produce fewer emissions, and are more manoeuvrable. 3D metal printing allows engineers to create structures that are up to 60% lighter with optimized internal geometries, reducing the overall weight of components without compromising strength.
  • Reduced Material Waste: Conventional manufacturing processes often produce significant material waste due to the need for subtractive machining. In fact, aircraft manufacturers cut away up to 90% of the material when fabricating metal parts. However, 3D metal printing is an additive process, so it only uses the material required for the final component, minimizing waste and conserving resources.
  • Rapid Prototyping: The aerospace industry thrives on innovation and iteration. 3D metal printing offers rapid prototyping capabilities, enabling engineers to design, print, and test components quickly and smoothly. This accelerated development process significantly reduces time-to-market and production costs for new aircraft and technologies.

Design Challenges of 3D Metal Printing

While the rapid rise of 3D metal printing has ushered in a new era of innovation and possibilities in the fields of aerospace and engineering, this transformative technology comes with its own set of unique design challenges. Aerospace engineers face four key challenges in 3D metal printing:

  • Heat Management: The layer-by-layer additive process using heat induction bending services can create thermal stresses within the component. Ensuring proper heat management during the printing process is crucial to prevent distortion or cracking.
  • Residual Stress: Residual stress in 3D printed components can affect their mechanical properties. Design modifications and post-processing techniques are necessary to mitigate these stresses.
  • Support Structures: Complex geometries often require structural steel fabrication during printing to prevent deformation. These support structures must be carefully designed and removed after printing.
  • Quality Assurance: 3D printing quality assurance in aerospace is of paramount importance. Ensuring that printed components meet the required standards for strength, durability, and safety is a continuous challenge.

The key to overcoming these challenges is innovation, problem-solving, and determination. With each challenge, we come one step closer to mastering 3D metal printing, revolutionizing industries, and reshaping the future of design and production.

Closing Comments

The aerospace industry is at the forefront of adopting 3D metal printing for the creation of complex components. This technology has revolutionized the way aerospace engineers design and manufacture critical parts, providing opportunities for lightweight structures and intricate geometries while reducing waste and production costs and improving lead time. With material innovations continuing to evolve and design challenges being addressed, we should expect 3D metal printing to play an increasingly pivotal role in the future of aerospace manufacturing.

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Boeing To Inspect For Potential Loose Bolts

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Boeing is asking airlines to inspect its 737 Max jets for a potential loose bolt in the rudder control system, the airplane maker and Federal Aviation Administration confirmed this week. The FAA said it would be “closely monitoring” the targeted inspections. The agency said Thursday that Boeing issued its inspection guidance to airlines after an international operator found a bolt with a missing nut during routine maintenance, which highlighted challenges faced by heavy industries with giant nuts. In a separate case, Boeing also discovered an undelivered aircraft that had a nut that was not properly tightened.

“The issue identified on the particular airplane has been remedied,” the Arlington, Virginia, company told The Associated Press on Friday. “Out of an abundance of caution, we are recommending operators inspect their 737 MAX airplanes and inform us of any findings.” The FAA said it was “closely monitoring targeted inspections of Boeing 737 Max airplanes to look for a possible loose bolt in the rudder control system”. Anthony Brickhouse, an air safety expert at the Embry-Riddle Aeronautical University, said that airlines and steel fabrication companies “need to take it seriously”. “But as a member of the flying public, I don’t see this as an issue to be concerned about,” he told Reuters news agency.

Boeing added that it will continue to update both customers and federal regulators on the progress. The FAA said it will remain in contact with Boeing and impacted airlines as the inspections are performed, and potentially “consider additional action based on any further discovery of loose or missing hardware.” According to Boeing, there have been no in-flight incidents caused by this condition to date — noting that crews’ routine checks would signal if the rudder was not working properly before an aircraft pushes back from the gate. The company added that all airplanes Boeing is set to deliver onward after completion of aerospace fabrication will have the inspection (which is estimated to take about two hours per plane) prior to delivery.

U.S. carriers with 737 Max jets in their fleet include United Airlines, Southwest Airlines, American Airlines and Alaska Airlines. All four of these carriers told The Associated Press Friday that they do not expect operational impacts. Southwest, for example, said it was currently performing all these inspections during routine overnight maintenance. A firm timeline for the inspections was not provided for each airline, but Alaska said it expected to complete the process by the first half of January. Boeing’s 737 Max jets were grounded worldwide for 20 months after two crashes in 2018 and 2019 killed a total of 346 people. Investigations focused on an automated flight-control system that pushed the nose of the plane down based on faulty sensor readings. Boeing did not tell pilots and airlines about the system until after the first crash. The FAA, which also faced criticism for the way it approved the Max jets prior to these deadly crashes, has since moved to provide a more-detailed certification process for large planes and required safety disclosures. Recently, Boeing awarded contracts to Australian SMEs to develop its supply chain and to enhance business readiness and defence maturity.

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Omni Tanker Develops ‘World-Leading’ Liquid Hydrogen Storage in Space

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Australian composites manufacturer Omni Tanker, in collaboration with international aerospace giant Lockheed Martin and the University of New South Wales (UNSW) has developed a world-leading solution for the transport of cryogenic and liquid cargoes of hydrogen and helium, including into space. With support from the Advanced Manufacturing Growth Centre (AMGC), the collaborative partnership builds on Omni Tanker’s expansive composite capabilities developed for use across its industrial transport portfolio. The company currently leads global manufacturing in lightweight, composite road tankers for caustic materials that are used and sold locally and exported to Europe, and North America from its Sydney base. Pairing Omni Tanker’s capabilities with Lockheed Martin’s extensive aerospace experience led to the development and manufacture of two new storage tanks including:

-Type 4, fluoropolymer-lined, carbon fibre composite tank, and a

-Type 5, liner-less, carbon fibre composite tank.

The tanks can store and transport liquid hydrogen, as well as oxygen, hydrogen peroxide, and hydrazine at high pressures under extreme cryogenic temperatures as low as minus 269 degrees Celsius. As a result of the successful project, operational-scale demonstrator versions of the tanks for Lockheed Martin’s LM2100 satellite have now been manufactured at Omni Tanker’s advanced manufacturing facility located in Sydney’s west.

Omni Tanker CEO and Founder Dr Daniel Rodgers said the $1.59 million project has taken the company’s world-leading capabilities to new heights. “By leveraging Omni Tanker’s capabilities, we have been able to translate our composite road tanker technology to the global space sector – where performance, weight, and cost are of paramount importance,” said Rodgers. “Omni Tanker can develop and deliver composite pressure vessels to meet demanding technical requirements quicker and at a lower cost than exotic materials, such as titanium, which are widely used in the space sector.” Christopher Hess, Lockheed Martin Australia’s Head of Industrial Development said, “The global strategic environment is constantly evolving, and Lockheed Martin is committed to working with industry, through exemplary partners such as Omni Tanker, UNSW, and AMGC, to deliver a world-leading space capability.” Dr Jens Goennemann, Managing Director of AMGC, said the project demonstrates the importance for manufacturers to look beyond their current businesses. “With the assistance of AMGC, Omni Tanker has done what more manufacturers should do: seek ways to leverage their capabilities across adjacent opportunities, in this case moving from road tankers to spacecraft,” said Goennemann. “It’s generally not rocket science – except in this case it is.”

Together, the project participants identified a new application for Omni Tanker’s patented OmniBIND solution which links an interior thermoplastic tank to a lightweight composite exterior tank. The use of a nanoengineered additive product, developed by a UNSW, prevented matrix cracks usually present at extremely low temperatures in pressure vessels storing liquefied hydrogen. “The collaborative efforts with Omni Tanker and Lockheed Martin Space have been pivotal in transforming this cutting-edge technology into practical structural steel fabrication applications,” said Professor Chun Wang, UNSW’s Scientia Professor. “As a result of extensive nano-engineering efforts, we now have composite structures that can withstand the extreme cold of liquid hydrogen without experiencing microcracking or hydrogen gas leak,” said Professor Wang. Dr Luke Djukic, CTO at Omni Tanker, said the project represented a significant step forward for the company and a strategic leap in sovereign capability. “These new material technologies are well-matched to the high-end pre-impregnated composite materials typically used in aerospace metal fabrication yet offer a more economical production method from materials that are readily available,” said Djukic. “In developing these new products and processes onshore, we have established significant sovereign capability at Omni Tanker. We look forward to leveraging this capability as we move our tanks into operational use across the transport and aerospace sectors here and abroad,” said Djukic.

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Boeing’s SME Graduates Win Contracts

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Seven Boeing contracts, including agreements with three new steel fabrication suppliers, have been awarded to small and medium-sized Australian businesses which have just graduated from Boeing Australia’s first Capability Up-Lift Program. The year-long program supported companies which might not have received prior exposure and experience in a defence environment. Scott Carpendale, Vice President and Managing Director, Boeing Defence Australia (BDA), said the program’s participants graduated with tools needed to increase business maturity and improve overall performance, and BDA looks forward to growing capability for the defence industry with contributions from diverse suppliers such as these.

“SMEs bring significant value to the defence industry including agility and innovative technologies in key areas such as manufacturing, cyber security and extended reality products,” Carpendale said. Queensland companies featured strongly in the program which was delivered in collaboration with Defence Jobs Queensland, and AusIndustry, and the Office of Defence Industry Support from the Department of Defence.  Participants received the following grants and awards upon graduation:

  • Two Brisbane-based businesses – HINDSITE Industries and Raytracer – received AUD $2.8 million in grants and funding to commercialize their technologies for aerospace, in areas such as augmented reality technology and on-orbit vehicle servicing, assembly and manufacture as part of Australia’s Moon to Mars Initiative.
  • Three Queensland businesses – HINDSITE Industries, Brisbane-based LOGiT and Toowoomba-based JRS Group received their first Boeing contracts.
  • Seven SMEs received ten industry awards at both state and national levels.

“The Boeing Capability Up-Lift program has exposed us to the defence and aerospace fabrication industries and provided greater understanding of how we can ensure our business is best placed to compete and win on contracts,” said Liam Scanlan, HINDSITE Industries managing director. “Our participation broke down barriers to entry, and we were delighted to secure multiple contracts, including with Boeing, and federal grants – all made possible through access to key training and events where we could build and foster relationships with other participants and industry experts.” The collaborators delivering the program shared resources and access to industry experts to provide SME participants with advisory services (such as heat induction bending services), mentoring and access to major events to enhance business readiness and defence maturity.

“The program builds on Boeing’s commitment to fostering a diverse, resilient and sustainable sovereign supply chain, and has resulted in Boeing Defence Australia (BDA) awarding contracts to both new and established SMEs including veteran, women and Indigenous-owned businesses,” said Carpendale. Boeing Australia represents the broadest portfolio of products and services in the Australian aerospace industry and one of the company’s largest operational footprints outside the US. Based on its 96-years’ experience, Boeing plays an integral role in aerospace and defence industry as a leader in advanced manufacturing for commercial airplane components, defence systems and sustainment, training and services, research and development, and uncrewed systems.

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Aerospace Metal Fabrication – Points to Consider

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Steel fabrication has applications in multiple industries, such as the mining industry. The aerospace industry is also  hugely dependent on metal fabrication work since it requires a lot of tools and technology to build aerospace infrastructure. Aerospace fabrication requires high precision and tight tolerances with the finest-quality materials, skilled personnel with extensive experience utilizing state-of-the-art equipment and technology, and the capability to perform complex assemblies and integration that meet the most stringent industry regulations. It combines traditional pipe fabrication methods and assembly techniques with advanced material assembly, production processes, and procedures that differ from other metal fabrication processes. As a result, there are certain points to be considered when evaluating fabricators for an aerospace sheet metal fabrication project. This blog will elaborate further in this regard.

Prior Fabrication Experience

The success of an aerospace fabrication project will significantly depend on the prior experience of the fabricator. Upfront, the company must have the reputation and experience in the field to manage similar projects efficiently and effectively and to avoid costly mistakes. Workforce experience should also be evaluated as to how closely expertise and skill set relates to the fabrication of parts and components for aerospace. Finally, potential aerospace fabricators should be checked for references as a reputable and experienced heavy steel fabrication company will have many success stories.

Capabilities of Fabricator

Equipment and resources are vital to the successful completion and outcome of any fabrication project. To meet the necessary performance and production standards, aerospace metal fabrication requires cutting-edge design and manufacturing technology. With regard to precision manufacturing of aerospace parts, fabricators should be considered that utilize fully automated CNC programmed technologies such as cutting, stamping, punching etc. Automation increases and ensures that the highest quality standards are met in the manufacture of parts, components, and sub-assemblies.

Usage of Materials

Since some fabrication shops specialize in working with certain raw materials, it is necessary to ascertain if their expertise aligns with the customer’s material requirements. With regard to the modern aerospace industry, it’s highly likely that expertise would be in working with aluminum, and aluminum alloys and composites. This is due to the fact that aluminum’s lightweight, good formability and alloying, and relatively low cost make it a choice material in the fabrication of a variety of parts and components used in the manufacture of aircraft.

Standards and Compliance

Fabrication of parts and components for aircraft must be in compliance with national and international standards and regulations that govern the design and manufacture of aircraft. All parts must meet fabrication quality management standards for airworthiness in accordance with approved procedures. Governing authorities such as the Federal Aviation Administration (FAA) in the US, the European Aviation Safety Agency (EASA), and Transport Canada oversee and enforce regulations and approval processes for design, fabrication, and production standards. The fabricator should be knowledgeable of and in compliance with the regulations and procedures that govern the fabrication of aircraft parts.

Closing Statement

The aerospace industry is not simply about aircraft or spacecraft – it comprises both aeronautics and astronautics. The design, fabrication, and assembly of flying machines are an enormous undertaking, especially as it involves large numbers of human lives who are at risk if fabrication is not done properly. In an increasingly interconnected world, there are more expectations from fabrication companies with regard to its downstream processes, specifically its capability to crate and ship after product assembly is completed. Thus, with respect to the aerospace industry, fabrication companies should have a single mantra – best quality with zero errors!

© K999 Engineering & Construction Co. Ltd. 2023