Utility of 3D Printing in Aerospace

3D Printing, also known as additive manufacturing or AM, is a process of creating a three-dimensional object from a digital design. Unlike traditional subtractive processes, 3D Printing is an additive process. Essentially, the 3D printer uses a digital blueprint to create a physical product. 3D Printing works by converting the design into a STL file (which is the most popular 3D Printing format) and then slicing it into layers. The 3D printer built head then deposits material layer by layer and builds up the object. The materials that can be used for 3D Printing include plastic, metals, resin, and polymers. With the rising popularity of 3D printers both among amateurs and enterprises, the availability of newer material is also increasing. Companies like Stratasys now offer a wide choice of raw material to suit all 3D Printing requirements.BioPrinting, multi-material 3D Printing and other such developments will further increase the scope for 3D Printing.

Some of the popular 3D Printing techniques include:

• Fused deposition modeling (FDM): This is the most common 3D Printing technology. It works by melting a thermoplastic filament and depositing it layer by layer to create a solid object. FDM printers are relatively affordable and easy to use, making them a good option for prototyping and low-volume production.
• Selective laser sintering (SLS): This technology uses a laser to sinter powdered materials, such as plastics or metals, together to create a solid object. SLS printers are more expensive than FDM printers, but they can produce parts with greater detail and accuracy.
• Stereolithography (SLA): This technology uses a laser to cure a liquid resin, layer by layer, to create a solid object. SLA printers can produce parts with very smooth surface
• Digital light processing (DLP): This technology is similar to SLA, but it uses a projector to cure the resin. This allows for faster Printing speeds.
• Polyjet Printing: Polyjet Printing uses a print head that dispenses multiple materials, such as plastics and elastomers, to create the object.It works by jetting tiny droplets of liquid photopolymer resin onto a build platform. These droplets are then cured or solidified instantly using ultraviolet (UV) light. This process is similar to how an inkjet printer deposits ink on paper, but in this case, it builds up layers of solid material. Polyjet printing produces intricate and finely detailed parts with smooth surface finishes.

These are just a few of the many 3D Printing technologies that are available today. The best technology for a particular application will depend on the materials, the desired properties of the part, and the requirement.The 3D Printing market is growing rapidly, and new technologies are being developed all the time. This is an exciting time to be involved in 3D Printing, and the possibilities are endless. One such field that is warming up to 3D Printing is the aerospace sector.

Aerospace – a Bird’s Eye View
Aerospace is a term used to collectively refer to the atmosphere and outer space. Aerospace activity is very diverse, with a multitude of commercial, industrial and military applications. Aerospace engineering consists of aeronautics and astronautics.Aeronautics is the science and technology of flight within the Earth's atmosphere. It includes the design, development, testing, and operation of aircraft, such as airplanes, helicopters, and unmanned aerial vehicles (UAVs). Astronautics is the science and technology of spacecraft and space flight. It includes the design, development, testing, and operation of spacecraft, such as rockets, satellites, landers, rovers and space stations.

Aerospace engineers play a vital role in the development of new technologies that help increase our knowledge by exploring the space around us. The aerospace industry is constantly evolving, and new challenges are always emerging. Some of the major challenges facing the aerospace industry today include the need to:

• develop more lighter and environmentally friendly aircrafts
• improve the safety of space flight
• develop new technologies for space exploration
• meet the growing demand for air travel

3D Printing, which offers advantages like Printing of complex geometries and a good choice of materials, is perfectly suited to help reduce the aircraft / spacecraft weight without compromising on strength. Here are a few instances where 3D Printing is helping aerospace companies:

• 3D Printing can be used to quickly and easily create prototypes of new aircraft parts or designs. This allows engineers to test and iterate on designs more quickly and efficiently, which can lead to better products.
• ISRO is using 3D Printing to develop new types of rocket engines. In 2021, ISRO successfully tested a 3D-printed rocket engine made from a special copper alloy that can withstand extremely high temperatures.
• 3D Printing is used to produce a variety of parts for aero planes like fuel nozzles, brackets, and heat shields. These parts are made from lightweight materials, which help to improve the fuel efficiency of the aircraft.
• 3D Printing is being used to produce lightweight and customized cabin interior parts, such as seat parts, cup holders, and lighting fixtures.
• 3D Printing is being used to create custom tools and fixtures for manufacturing aerospace parts.This can help to improve the efficiency and accuracy of the manufacturing process.
• 3D Printing can be used to produce spare parts for commercial airplanes, which can be useful in remote or difficult-to-reach locations.
• 3D Printing can be used to personalize aircraft parts to the specific needs of each aircraft or operator. This can improve performance, safety, or comfort.
• 3D Printing is being used to repair and remanufacture damaged aerospace parts. It reduces the cost and downtime associated with aircraft maintenance.

Some of the most popular choice of 3D Printing technologies in the aerospace sector includesFused deposition modeling (FDM), Selective laser sintering (SLS), Stereolithography (SLA), digital light processing (DLP) and Polyjet technology. 3D Printing is a rapidly evolving technology with the potential to revolutionize the space industry. Market leaders like Stratasys are leveraging their expertise in the field of 3D printers to manufacture printers that are more accurate, faster, and can work with a variety of materials. A few Stratasys 3D printers that are useful in the aerospace sector include the Fortus 450mc (FDM), J850 (Polyjet) and the Fortus 900mc (FDM), and Origin One P3 (DLP). Needless to say, availability of raw material for 3D printing that is durable also augments their utility. As examples, Stratasys FDM materials like ULTEM™ 9085 are an excellent choice for applications that require high chemical tolerance. ULTEM™ 1010 resin, a robust polyetherimide (PEI) thermoplastic, stands out as a high-performance 3D printing material as well.

As the technology continues to develop, 3D printers and 3D Printing are expected to play an even greater role in the design, manufacturing, and maintenance of aero planes and space vehicles.