{"id":40513,"date":"2020-06-10T13:16:17","date_gmt":"2020-06-10T17:16:17","guid":{"rendered":"https:\/\/www.shapeways.com\/blog\/?p=40513"},"modified":"2021-07-16T17:10:53","modified_gmt":"2021-07-16T21:10:53","slug":"why-is-the-aircraft-industry-using-3d-printing","status":"publish","type":"post","link":"https:\/\/www.shapeways.com\/blog\/why-is-the-aircraft-industry-using-3d-printing","title":{"rendered":"Why Is The Aircraft Industry Using 3D Printing?"},"content":{"rendered":"\n<p class=\"wp-block-paragraph\">While as of the time of writing, the air\ntravel industry is facing significant difficulties in the face of\npandemic-driven reductions in flights, for many years aircraft have been\nproving one of the fastest-growing applications for 3D printing around the world.\nWe expect that air travel will resume in the not-too-distant future &#8212; and that\nwill see demand for state-of-the-art aircraft on the rise. Some manufacturers\nmay even be using this unanticipated downtime to revamp their fleets, building\nup digital inventories to supply aging aircraft and using advanced\nmanufacturing technologies to create the next generations of aircraft.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Let\u2019s dive in to find out just why the\naircraft industry is using 3D printing.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>A Fit\nFor 3D Printing<\/strong><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Aerospace is a unique fit for many of the\nmost-touted benefits of 3D printing:<\/p>\n\n\n\n<ul class=\"wp-block-list\"><li>Part consolidation<\/li><li>Lightweighting<\/li><li>Complex geometries (\u201cfreedom of design\u201d)<\/li><li>Rapid prototyping<\/li><li>Low-volume production<\/li><li>Digital inventory<\/li><\/ul>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Let\u2019s look at each of these areas to see how\nthe production of aircraft can make use of these benefits.<\/p>\n\n\n\n<h4 class=\"wp-block-heading\"><em>Part\nConsolidation<\/em><\/h4>\n\n\n\n<p class=\"wp-block-paragraph\">The weakest point in an assembly is where it\nhas been, well, assembled. When it comes to aircraft, such a weakness could\nbecome a point of critical failure, endangering human lives.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">By consolidating multiple components of a part\ninto a single 3D printed build, the number of assembly points is necessarily\nreduced. The unique geometries possible with 3D printing can reduce a part that\ntypically has dozens or hundreds of parts to few &#8212; or to one single part. With\nno welding, riveting, or other fastening needed to keep the part together, not\nonly are SKUs reduced, but so too are potential points of failure.<\/p>\n\n\n\n<h4 class=\"wp-block-heading\"><em>Lightweighting<\/em><\/h4>\n\n\n\n<p class=\"wp-block-paragraph\">Every ounce of weight matters when it comes to\nequipment meant to fly. Lighter-weight parts means less fuel, improving not\nonly the carbon footprint of a flight but also the cost to fly.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Materials innovations in 3D printing are\nseeing constant improvements in different metals and polymers approved for use\nin different equipment. Many of these engineering-grade materials are familiar\nto those who have worked with them in traditional manufacturing &#8212; translating\nthese formulations into 3D printable materials is bringing their capabilities\ntogether with part consolidation and other time- and material-reducing benefits\nto create altogether lighter final parts.<\/p>\n\n\n\n<h4 class=\"wp-block-heading\"><em>Freedom\nof Design<\/em><\/h4>\n\n\n\n<p class=\"wp-block-paragraph\">Many working with design for additive\nmanufacturing (DfAM) like to proclaim that the technology offers great \u201cfreedom\nof design,\u201d as complex geometries impossible to make with other manufacturing\nprocesses are for the first time possible.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Design methods like topology optimization and\ngenerative design are developing new shapes never before dreamed of that can be\ncreated only by 3D printing. These complex, often lattice-like designs not only\nreduce weight by including material only where necessary, but are often stronger\nthan legacy designs. While certain constraints of course still exist, and may\nvary by 3D printing technology and material used, these are in many ways\nsignificantly reduced from those seen in traditional, subtractive manufacturing\nprocesses. New interior and exterior aircraft components can be designed to\nreplace stodgy original parts, adding both design finesse and extreme\nfunctionality.<\/p>\n\n\n\n<h4 class=\"wp-block-heading\"><em>Rapid\nPrototyping<\/em><\/h4>\n\n\n\n<p class=\"wp-block-paragraph\">The earliest use of 3D printing is also its original nomenclature: <a href=\"https:\/\/www.shapeways.com\/business\/rapid-prototyping-services\" target=\"_blank\" rel=\"noreferrer noopener\" aria-label=\"rapid prototyping (opens in a new tab)\">rapid prototyping<\/a>.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Quickly going from a napkin sketch idea to a\nCAD design to a first prototype &#8212; and then a second, third, and so on &#8212;\nspeeds up the time-to-market for new products. While traditional manufacturing\nmay require multiple iterations to be sent back and forth over weeks or months,\nthe fast-paced aircraft industry can see much faster turnaround when designs\ncan be created and finalized within days or weeks.<\/p>\n\n\n\n<h4 class=\"wp-block-heading\"><em>Low-Volume\nProduction<\/em><\/h4>\n\n\n\n<p class=\"wp-block-paragraph\">As large as the aerospace industry is, by\ntotal volume the sheer number of aircraft produced is relatively small compared\nto, say, automotive or appliance production.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">High-value, low-volume production is a perfect\nfit for 3D printing. Whereas many traditional manufacturing processes require\nexpensive tooling and molding to be made, creating economies of scale for mass\nproduction, no molding is necessary for additive manufacturing. One or a few\npieces may be made at a time &#8212; including different designs on the same build\nplate &#8212; with no additional molding or tooling costs. The point of inflection for\nadditive versus traditional manufacturing typically requires hundreds or\nthousands of parts to be made before traditional techniques are more\ncost-effective &#8212; and while that may ultimately reduce costs to pennies per\ninjection molded part, before that crossover point, 3D printing is more\ncost-effective. This is especially the case when using high-value metal\npowders, when material savings are imperative; 3D printing eliminates\nsignificant waste of material as only the material needed for a given build need\nbe used, and much else can be recycled, rather than cutting away and wasting\nmaterial from solid blocks in subtractive manufacturing processes.<\/p>\n\n\n\n<h4 class=\"wp-block-heading\"><em>Digital\nInventory<\/em><\/h4>\n\n\n\n<p class=\"wp-block-paragraph\">When an aircraft is approaching the end of its\nuseful life, often it can be salvaged through replacing certain parts to keep\nit flying. This is often done through use of physical warehouses, where these\nspare parts were stored on shelves until needed. These spare parts, in most\ncases, were made at the same time as the original mass-produced OEM parts, set\naside to await replacement demand for worn parts. If that demand never comes,\nthough, they were a waste of not only the time and cost of producing them, but\nalso of storing them on shelves for however many years. Worse, if that demand\ncomes but spares are out of stock &#8212; especially those forever out of production\n&#8212; the lack of a small part may ground a plane.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Rather than physically keeping goods on\nshelves, digital fabrication methods allow for storage of a design file that\ncan be 3D printed on demand. 3D printing a replacement part allows for only\nthose parts needed to ever be made &#8212; again without need for first producing\ncostly molding or tooling. These on-demand spare parts can also be made\nanywhere with the appropriate technology, rather than awaiting OEM delays that\ncan all too easily run up into weeks or months.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>Flying\nHigh With 3D Printing<\/strong><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">The production of aircraft, from prototype to spare parts, is increasingly benefitting from the use of 3D printing in the supply chain. Decentralized production, new design possibilities, and reductions in time, materials, and costs are offering new ways for aircraft to keep flying high.<\/p>\n\n\n\n<div class=\"wp-block-image\"><figure class=\"aligncenter size-large is-resized\"><a href=\"https:\/\/shapeways.com\/industry\/aerospace\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2019\/02\/learn-more_.png\" alt=\"\" class=\"wp-image-39411\" width=\"137\" height=\"60\"\/><\/a><\/figure><\/div>\n","protected":false},"excerpt":{"rendered":"<p>While as of the time of writing, the air travel industry is facing significant difficulties in the face of pandemic-driven&#8230;<\/p>\n","protected":false},"author":160,"featured_media":40516,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[510],"tags":[555,2553,593,2552,2549,2551,2547,2550,2546,849,2545],"class_list":["post-40513","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-3d-printing-industry","tag-3d-printing","tag-3d-printing-applications","tag-aerospace","tag-aircraft-production","tag-design-freedom","tag-digital-inventory","tag-lightweighting","tag-low-volume-manufacturing","tag-part-consolidation","tag-production","tag-rapid-prototyping"],"thumbnail":"https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2020\/06\/Cover-iStock-610956648.jpg","yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v23.9 (Yoast SEO v23.9) - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Why Is The Aircraft Industry Using 3D Printing? - Shapeways Blog<\/title>\n<meta name=\"description\" content=\"3d printing in aircraft is becoming more and more popular. We&#039;re going to dive in to find out exactly why the aircraft industry is using 3d printing and not other solutions.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.shapeways.com\/blog\/why-is-the-aircraft-industry-using-3d-printing\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"Sarah Goehrke\" \/>\n\t<meta name=\"twitter:label2\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"5 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\/\/schema.org\",\"@graph\":[{\"@type\":\"Article\",\"@id\":\"https:\/\/www.shapeways.com\/blog\/why-is-the-aircraft-industry-using-3d-printing#article\",\"isPartOf\":{\"@id\":\"https:\/\/www.shapeways.com\/blog\/why-is-the-aircraft-industry-using-3d-printing\"},\"author\":{\"name\":\"Sarah Goehrke\",\"@id\":\"https:\/\/prodshapeblog.wpenginepowered.com\/#\/schema\/person\/60d4ba6c514cdadd44d142e62d3421cd\"},\"headline\":\"Why Is The Aircraft Industry Using 3D Printing?\",\"datePublished\":\"2020-06-10T17:16:17+00:00\",\"dateModified\":\"2021-07-16T21:10:53+00:00\",\"mainEntityOfPage\":{\"@id\":\"https:\/\/www.shapeways.com\/blog\/why-is-the-aircraft-industry-using-3d-printing\"},\"wordCount\":1057,\"commentCount\":0,\"publisher\":{\"@id\":\"https:\/\/prodshapeblog.wpenginepowered.com\/#organization\"},\"image\":{\"@id\":\"https:\/\/www.shapeways.com\/blog\/why-is-the-aircraft-industry-using-3d-printing#primaryimage\"},\"thumbnailUrl\":\"https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2020\/06\/Cover-iStock-610956648.jpg\",\"keywords\":[\"3D printing\",\"3d printing applications\",\"aerospace\",\"aircraft production\",\"design freedom\",\"digital inventory\",\"lightweighting\",\"low volume manufacturing\",\"part consolidation\",\"production\",\"rapid prototyping\"],\"articleSection\":[\"3D Printing Industry\"],\"inLanguage\":\"en-US\",\"potentialAction\":[{\"@type\":\"CommentAction\",\"name\":\"Comment\",\"target\":[\"https:\/\/www.shapeways.com\/blog\/why-is-the-aircraft-industry-using-3d-printing#respond\"]}]},{\"@type\":\"WebPage\",\"@id\":\"https:\/\/www.shapeways.com\/blog\/why-is-the-aircraft-industry-using-3d-printing\",\"url\":\"https:\/\/www.shapeways.com\/blog\/why-is-the-aircraft-industry-using-3d-printing\",\"name\":\"Why Is The Aircraft Industry Using 3D Printing? - Shapeways Blog\",\"isPartOf\":{\"@id\":\"https:\/\/prodshapeblog.wpenginepowered.com\/#website\"},\"primaryImageOfPage\":{\"@id\":\"https:\/\/www.shapeways.com\/blog\/why-is-the-aircraft-industry-using-3d-printing#primaryimage\"},\"image\":{\"@id\":\"https:\/\/www.shapeways.com\/blog\/why-is-the-aircraft-industry-using-3d-printing#primaryimage\"},\"thumbnailUrl\":\"https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2020\/06\/Cover-iStock-610956648.jpg\",\"datePublished\":\"2020-06-10T17:16:17+00:00\",\"dateModified\":\"2021-07-16T21:10:53+00:00\",\"description\":\"3d printing in aircraft is becoming more and more popular. 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