the future of additive manufacturing in aerospace

1 1

BOE 011911-058 Public Release Copyright © 2012 Boeing. All rights reserved.

Michael Hayes

Boeing Research and Technology

The Boeing Company

1

The Future of Additive Manufacturing in Aerospace

- Where we are going, we don’t need roads-

Trends in Advanced Machining,

Manufacturing & Materials

September 12-13, 2012

Chicago, IL

Engineering, Operations & Technology | Boeing Research & Technology Manufacturing Technology

| 2 | 2 | 2

Objectives

Part(s)

What is Additive Manufacturing (AM)?

Why does Boeing care about AM?

Where is AM today within Boeing?

Where is AM going within Boeing?

Copyright © 2012 Boeing. All rights reserved.


| 3 | 3 | 3

Objectives

Part(s)







| 4 | 4 | 4


Additive

Manufacturing



| 5 | 5 | 5

Part(s)


Additive

Manufacturing



| 6 | 6 | 6

Part(s)


Additive

Manufacturing

FDM

SLA



| 7 | 7 | 7

Part(s)


Additive

Manufacturing

FDM

SLA



| 8 | 8 | 8


Additive

Manufacturing

FDM

SLA



| 9 | 9 | 9

Part(s) Stratasys

Mojo Stratasys

Fortus 900mc

Increasing Cost

Increasing Capability

e.g. Size, Materials


Low Cost Desktop Higher Dollar Standalone



| 10 | 10 | 10

Part(s) Stratasys

Mojo Stratasys

Fortus 900mc

Increasing Cost

Increasing Capability

e.g. Size, Materials


Low Cost Desktop Higher Dollar Standalone

3D Printing Additive Manufacturing

Increasingly blurring



| 11 | 11 | 11


Additive Manufacturing (AM) Definition

The process of joining materials to make objects from 3D model

data, usually layer upon layer - ASTM F42

CAD Model Machine

Part(s)

One Machine – One Process – Multiple Applications Copyright © 2012 Boeing. All rights reserved.


| 12 | 12 | 12

Objectives

Part(s)







| 13 | 13 | 13

Why Does Boeing Care About AM?

1. Weight

2. Cost

Given that a system will meet all performance requirements including

high safety considerations……..

What is important to the Boeing design engineer?

1. Cost

2. Weight

First…..



| 14 | 14 | 14


1. Weight

2. Cost

1. Cost

2. Weight

Additive Manufacturing has the potential to reduce both



| 15 | 15 | 15


Part(s)

How?

One example…. Combining multiple parts into one



| 16 | 16 | 16


Part(s)

How?

One example…. Combining multiple parts into one

Weight

Less parts

Unitization

Structural efficiency

Cost

Less parts (reduced assembly time)

Unitization

Structural efficiency



| 17 | 17 | 17


How?

Lead Time to Product One example….

No tools required



| 18 | 18 | 18


How?


No tools required

Design

Analysis

Manufacturing

Due to digital capability –

Design & Analysis are faster than ever before



| 19 | 19 | 19


Part(s)

How?


Flying Prototype

Vehicle

36 mo

24 mo

18 mo

Design

Analysis

Manufacturing

Pressure is on Manufacturing

…next step is to also embrace digital capability



| 20 | 20 | 20

Objectives

Part(s)







| 21 | 21 | 21


Part(s)

CNC Machining (Subtractive)

1930 1950 1940 1970 1960 1980 2000 1990 2010

NC Machine

Invented

Robotic process

reaches

manufacturing

maturity

Applied across

multiple

industries

Take one step back…..



| 22 | 22 | 22


Part(s)

Composites

1930 1950 1940 1970 1960 1980 2000 1990 2010

NC Machine

Invented

Robotic process

reaches

manufacturing

maturity

Applied across

multiple

industries

Fiberglas

Patented

Carbon Fiber

production

begins

All fiberglas

aircraft;

H-301

Dragonfly

787

commercial

aircraft first

flight





| 23 | 23 | 23


1930 1950 1940 1970 1960 1980 2000 1990 2010

NC Machine

Invented

Robotic process

reaches

manufacturing

maturity

Applied across

multiple

industries

Fiberglas

Patented

Carbon Fiber

production

begins

All fiberglas

aircraft;

H-301

Dragonfly

787

commercial

aircraft first

flight

entire history of

RP/AM

First

production

SLS nylon

ECS ducts

Composites





| 24 | 24 | 24


Part(s)

How it is used today…..

• 200 different part numbers on 10 production platforms

• Tooling on more than 15 programs

• Prototypes

Parts are system components and are all non-structural, non-flight critical

Tooling is across the board – forming, shop aids, drill templates, assembly,…



| 25 | 25 | 25

Objectives

Part(s)







| 26 | 26 | 26


Part(s)

Structural & Multifunctional Components

Where does Boeing want AM to go…..?

…not just limited to sub-system parts…



| 27 | 27 | 27


Part(s)

• Larger build sizes

• Multiple materials

• Process Control & Feedback

• Design & Analysis Tools

• Reliability

What is needed?

Structural & Multifunctional Components

Where does Boeing want AM to go…..?

…not just limited to sub-system parts



| 28 | 28 | 28

Additive Manufacturing (AM) Definition

The process of joining materials to make objects from 3D model

data, usually layer upon layer - ASTM F42

CAD Model Machine

Component(s)

One Machine – One Process – Multiple Applications


?



| 29 | 29 | 29


Part(s)

So that….



| 30 | 30 | 30


Part(s)

THANK YOU !


| 31 | 31 | 31

the future of additive manufacturing in aerospace

Documents