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Amaze project aims to take 3D printing 'into metal age' | Amaze project aims to take 3D printing 'into metal age' |
(about 14 hours later) | |
The European Space Agency has unveiled plans to "take 3D printing into the metal age" by building parts for jets, spacecraft and fusion projects. | The European Space Agency has unveiled plans to "take 3D printing into the metal age" by building parts for jets, spacecraft and fusion projects. |
The Amaze project brings together 28 institutions to develop new metal components which are lighter, stronger and cheaper than conventional parts. | The Amaze project brings together 28 institutions to develop new metal components which are lighter, stronger and cheaper than conventional parts. |
Additive manufacturing (or "3D printing") has already revolutionised the design of plastic products. | Additive manufacturing (or "3D printing") has already revolutionised the design of plastic products. |
Printing metal parts for rockets and planes would cut waste and save money. | Printing metal parts for rockets and planes would cut waste and save money. |
The layered method of assembly also allows intricate designs - geometries which are impossible to achieve with conventional metal casting. | The layered method of assembly also allows intricate designs - geometries which are impossible to achieve with conventional metal casting. |
Parts for cars and satellites can be optimised to be lighter and - simultaneously - incredibly robust. | Parts for cars and satellites can be optimised to be lighter and - simultaneously - incredibly robust. |
Tungsten alloy components that can withstand temperatures of 3,000C were unveiled at Amaze's launch on Tuesday at London's Science Museum. | Tungsten alloy components that can withstand temperatures of 3,000C were unveiled at Amaze's launch on Tuesday at London's Science Museum. |
At such extreme temperatures they can survive inside nuclear fusion reactors and on the nozzles of rockets. | At such extreme temperatures they can survive inside nuclear fusion reactors and on the nozzles of rockets. |
"We want to build the best quality metal products ever made. Objects you can't possibly manufacture any other way," said David Jarvis, Esa's head of new materials and energy research. | "We want to build the best quality metal products ever made. Objects you can't possibly manufacture any other way," said David Jarvis, Esa's head of new materials and energy research. |
"To build a [fusion reactor], like Iter, you somehow have to take the heat of the Sun and put it in a metal box. | "To build a [fusion reactor], like Iter, you somehow have to take the heat of the Sun and put it in a metal box. |
"3,000C is as hot as you can imagine for engineering. | "3,000C is as hot as you can imagine for engineering. |
"If we can get 3D metal printing to work, we are well on the way to commercial nuclear fusion." | "If we can get 3D metal printing to work, we are well on the way to commercial nuclear fusion." |
Additive manufacturing with metal is not new; General Electric, for example, has used the technique to make fuel injectors for one of its aircraft engines. China claims to be using 3D printing to manufacture load-bearing components in aircraft. | Additive manufacturing with metal is not new; General Electric, for example, has used the technique to make fuel injectors for one of its aircraft engines. China claims to be using 3D printing to manufacture load-bearing components in aircraft. |
And in July, Nasa announced that it had successfully tested a 3D-printed rocket engine part. | And in July, Nasa announced that it had successfully tested a 3D-printed rocket engine part. |
Amaze is a loose acronym for Additive Manufacturing Aiming Towards Zero Waste and Efficient Production of High-Tech Metal Products. | Amaze is a loose acronym for Additive Manufacturing Aiming Towards Zero Waste and Efficient Production of High-Tech Metal Products. |
The 20m-euro project brings together 28 partners from European industry and academia - including Airbus, Astrium, Norsk Titanium, Cranfield University, EADS, and the Culham Centre for Fusion Energy. | The 20m-euro project brings together 28 partners from European industry and academia - including Airbus, Astrium, Norsk Titanium, Cranfield University, EADS, and the Culham Centre for Fusion Energy. |
Factory sites are being set up in France, Germany, Italy, Norway and the UK to develop the industrial supply chain. | Factory sites are being set up in France, Germany, Italy, Norway and the UK to develop the industrial supply chain. |
Amaze researchers have already begun printing metal jet engine parts and aeroplane wing sections up to 2m in size. | Amaze researchers have already begun printing metal jet engine parts and aeroplane wing sections up to 2m in size. |
These high-strength components are typically built from expensive, exotic metals such as titanium, tantalum and vanadium. | These high-strength components are typically built from expensive, exotic metals such as titanium, tantalum and vanadium. |
Using traditional casting techniques often wastes precious source material. | Using traditional casting techniques often wastes precious source material. |
Additive manufacturing - building parts up layer-on-layer from 3D digital data - produces almost "zero waste". | Additive manufacturing - building parts up layer-on-layer from 3D digital data - produces almost "zero waste". |
"To produce one kilo of metal, you use one kilo of metal - not 20 kilos," says Esa's Franco Ongaro. | "To produce one kilo of metal, you use one kilo of metal - not 20 kilos," says Esa's Franco Ongaro. |
"We need to clean up our act - the space industry needs to be more green. And this technique will help us." | "We need to clean up our act - the space industry needs to be more green. And this technique will help us." |
Printing objects as a single piece - without welding or bolting - can make them both stronger and lighter. | Printing objects as a single piece - without welding or bolting - can make them both stronger and lighter. |
A weight reduction of even 1kg for a long-range aircraft will save hundreds of thousands of dollars over its lifespan. | |
"Our ultimate aim is to print a satellite in a single piece. One chunk of metal, that doesn't need to be welded or bolted," said Jarvis. | "Our ultimate aim is to print a satellite in a single piece. One chunk of metal, that doesn't need to be welded or bolted," said Jarvis. |
"To do that would save 50% of the costs - millions of euros." | "To do that would save 50% of the costs - millions of euros." |
But Jarvis is candid about the problems and inefficiencies that still need to be overcome - what he calls the "dirty secrets" of 3D printing. | But Jarvis is candid about the problems and inefficiencies that still need to be overcome - what he calls the "dirty secrets" of 3D printing. |
"One common problem is porosity - small air bubbles in the product. Rough surface finishing is an issue too," he said. | "One common problem is porosity - small air bubbles in the product. Rough surface finishing is an issue too," he said. |
"We need to understand these defects and eliminate them - if we want to achieve industrial quality. | "We need to understand these defects and eliminate them - if we want to achieve industrial quality. |
"And we need to make the process repeatable - scale it up. | "And we need to make the process repeatable - scale it up. |
"We can't do all this unless we collaborate between industries - space, fusion, aeronautics. | "We can't do all this unless we collaborate between industries - space, fusion, aeronautics. |
"We need all these teams working together and sharing." | "We need all these teams working together and sharing." |