Today, we’re delving into the world of real-life 3D printed parts for commercial aircraft, with a specific focus on Airbus. Materialize, a 3D printing service provider, has received qualification from Airbus to manufacture flight-ready polymer components using EOS’s SLS (Selective Laser Sintering) printing technology. This development marks a significant leap in the aerospace sector’s exploration of additive manufacturing.
Unlocking Airbus’s Global Potential
Airbus’s qualification of Materialize’s 3D printing capabilities signifies a pivotal moment. The approved polymer, flame-retardant polyamide powder PA 2241 FR, showcases EOS’s prowess in the 3D printing domain. With this achievement, Materialize and EOS become the first companies to receive approval to print parts under Airbus’s stringent process specification, AIPS 0307022. Notably, these parts can be deployed across Airbus’s vast global operations, spanning a multitude of divisions.
EOS’s PA12-based material boasts exceptional flame-retardant properties and a remarkably high refresh rate, rendering it exceptionally cost-effective for manufacturing flight-ready components. It complies with various fire, smoke, and toxicity requirements without necessitating an additional coating or primer.
Traditionally Metal Dominated, Now Polymer’s Triumph
Traditionally, 3D printed components for aerospace applications leaned toward high-strength, high-temperature metals. These components were primarily utilized internally for items like air ducts and brackets. However, the introduction of flame-retardant polymer 3D printing materials is a significant milestone. The adoption of polymer materials paves the way for a new era in aerospace additive manufacturing.
Expanding the Range of 3D Printing Solutions
The qualification, AIPS 0307022, extends beyond material approval; it encompasses the entire 3D printing process, developed for EOS systems such as the 770 polymer printer. Airbus had previously qualified ULTEM 9085 for FDM (Fused Deposition Modeling) processes. Materialize now delivers two flight-ready 3D printing solutions to Airbus, emphasizing the company’s commitment to embracing innovation.
Materialize and Airbus: A Long-Term Partnership
Materialize has been a significant contributor to Airbus’s aerospace endeavors over the years, starting with components for the A350 aircraft. The A350 series alone utilizes approximately a hundred different flight-ready 3D printed parts, amounting to an annual production of around 26,000 components. This new qualification enables Airbus to expand the use of 3D printed components to other aircraft models in its lineup, including the A320, A330, and more.
3D Printing: A Game-Changer in Aerospace
The aerospace sector is increasingly recognizing the value of additive manufacturing. From Fused Deposition Modeling to SLS technology, industrial 3D printing plays a pivotal role in enhancing efficiency, reducing costs, and broadening the possibilities in aircraft production. Companies like Airbus are driving the adoption of 3D printing technologies, emphasizing their readiness to embrace innovation in the aerospace industry.
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