Integrating 3D Printing in the Design Workflow
3D printing is implemented at all stages of the design workflow for applications in the aerospace industry. Here is how:
Design communication
Designs in the aerospace industry often begin as concept models showcasing a component of an aircraft. These are often also regularly used for aerodynamic testing, which is of critical importance for aerospace. SLA and Material Jetting are used to produce high detail, smooth, scale models of aerospace designs. Accurate models allow design intention to be clearly communicated and showcase the overall form of a concept.
Validation stage
Prototyping using 3D printing is now commonplace in the aerospace industry. From a full-size landing gear enclosure printed rapidly with low-cost FDM, to a high-detail, full-color control board concept model, there is a 3D printing process suited to every prototyping need. Engineering materials for 3D printing also allow for full testing and validation of prototype performance.
Pre-production
One of the areas 3D printing has been most disruptive and valuable is the production of low-cost rapid tooling for injection molding, thermoforming and jigs and fixtures. Within the aerospace industry, this allows for tooling to be quickly manufactured at a low cost and then used to produce low to medium runs of parts. This validation mitigates the risk when investing in high-cost tooling at the production stage and can also provide production components for quantities up to 5,000 to 10,000 parts.
Production
Because production volumes in the aerospace industry are generally large (more than 70,000 parts per year) 3D printing has predominantly been used in the past as a prototyping solution rather than the manufacturing of end parts. Improvements in the size of industrial printers, the speed they are able to print at and the materials that are available mean that 3D printing is now a viable option for many medium-sized production runs, particularly for high-end interior build-outs.
Customization
3D printing technologies have a significant impact on the aerospace industry when the cost of highly complex one-off components can be justified by a substantial improvement in aircraft performance: the average corporate aircraft travel 75,000 miles per month and a single component that was designed and manufactured with 3D printing reduces air drag by 2.1%, reducing fuel costs by 5.41%! Small adjustments like this example affect life in a huge way.
Parts can be tailored to a specific aircraft (custom, lightweight bracketry) or type of aircraft (cargo, passenger or even helicopter). 3D printing also provides part consolidation and topology optimization of many custom aerospace components. This is further highlighted in the case study in a latter section.