Metal 3D printing technology is reshaping our thinking about design and manufacturing in the aerospace industry. By leveraging the benefits of using 3D printing and automating design, businesses have achieved impressive successes and significant cost savings. In this article, we will explore 2 successful cases of companies using metal 3D printing technology with Nikon SLM Solutions printers, from optimizing designs to unique lattice structures.
MONOLITHIC THRUST CHAMBER – MONOLITHIC ROCKET THRUSTER DESIGN
In this case, CellCore GmbH and Nikon SLM Solutions collaborated to optimize the design and production of a monolithic thrust chamber for rockets. This is an example of using metal 3D printing technology combined with lattice structures to improve functionality and optimize the manufacturing process in the aerospace industry.
1. Functionality Optimization:
This part was designed with an integrated heat dissipation lattice system directly into its wall, improving cooling through the integration of lattice structures within the combustion chamber wall. The heat dissipation lattice was optimized with a lattice structure. This not only helps improve cooling efficiency but also contributes to enhancing stability and load-bearing capacity of the product.
Structural cooling design developed by CellCore
This part is made from IN718 nickel alloy on an SLM®280 printer. With the advantage of withstanding temperatures up to 700°C, this is a material commonly used for aircraft components and gas turbines, as well as other parts that must operate in high-temperature environments.
2. Weight Reduction:
Applying a lattice structure not only helps optimize cooling efficiency but also contributes to reducing the weight of the component. Additionally, by harnessing the power of 3D printing technology, the thrust component is designed as a monolithic structure with a lightweight design and integrates multiple features into the component's walls, another crucial factor in significantly reducing weight. The weight of the component was previously 2000g, but after 3D printing with an integrated lattice structure, the weight was reduced to 1300g, a 35% reduction.
Joint development project between CellCore GmbH and SLM Solutions
3. Process Optimization:
Previously, the manufacturing process for this component took a minimum of six months using traditional methods. The component would be produced as separate small parts and then assembled together. However, with metal 3D printing technology using Nikon SLM Solutions printers, this time was reduced to 3 days, 5 hours, and 34 minutes to produce a finished product.
The part is printed in one piece within 4 days
KRUEGER GOOSENECK – KRUEGER GOOSENECK DESIGN WITH LATTICE STRUCTURE
This case will show readers the clear benefits of using additive manufacturing technology combined with innovative design techniques in aerospace component production. Through strategic redesign and partnership with SLM Solutions, ASCO Industries has not only achieved significant weight reduction and efficiency gains but has also demonstrated the potential of advanced manufacturing technologies in the aerospace industry.
1. Optimization for Weight Reduction and Increased Strength:
Previously, ASCO Industries initially designed a gooseneck part for machining in a traditional manner, made from high-strength corrosion-resistant steel, weighing 2050g.
Left: Traditional design; Right: Optimized design
After partnering with Nikon SLM Solutions, design engineers redesigned with the principle of Design for Additive Manufacturing (DfAM). The new part uses specially designed lattice structures that can only be produced using 3D printing technology to reduce weight while still ensuring the functionality of the product.
Results from 3D Printing: Weight reduced from 2050g to 1416g, achieving a weight reduction of 31% while maintaining the structural integrity of the part.
2. Improved Buy-to-Fly Ratio and Reduced Machining Time:
Buy-to-Fly Ratio: The original machined version had a buy-to-fly ratio of 17, while the part using 3D printing techniques reduced this ratio to 1.5 after post-print processing.
Machining Time: The original machining time from a steel block was 4.5 hours, significantly reduced thanks to 3D printing technology. Although the new design with a lattice structure has a fairly complex surface structure, the post-print processing is relatively simple.
CONCLUSION
In the context of the aerospace industry, applying metal 3D printing technology has brought significant benefits to companies like ASCO Industries and CellCore GmbH. By redesigning components and closely collaborating with Nikon SLM Solutions, they have not only achieved significant weight reduction and increased efficiency but also demonstrated the potential of advanced manufacturing technologies in this industry.
Metal 3D printing technology is not just a progression in the manufacturing process but also an opportunity for engineers to continue researching and applying it to optimize the design and manufacturing processes of components in the aerospace industry. The combination of innovative design and the flexible manufacturing capabilities of metal 3D printing opens new doors for progress and development in the future.
Learn More
To understand more about the applications of Metal 3D Printing Technology in the aerospace industry, you can refer to other articles by Vinnotek:
How Metal 3D Printing Technology has improved drive supports for aircraft?
Metal 3D Printing - Selective Laser Melting (SLM)
With the continuous development of technology, not only the aerospace industry but also other industries will continue to witness significant innovation and progress, and metal 3D printing technology is one of the key factors in that journey.
Vinnotek is a reliable partner in providing design services for critical components in many industries, such as aerospace, automotive, energy, and healthcare. We not only bring the benefits of advanced 3D printing technology but also are the official representative of Nikon SLM Solutions - one of the world's leading metal 3D printing machine manufacturers.
With a combination of creativity and professionalism, we are committed to accompanying your business to optimize design, reduce manufacturing costs, and improve work efficiency. Contact Vinnotek today to experience innovation and advancement in your industry.
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