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Additive manufacturing (AM) is a revolutionary new way to build parts where raw materials are printed into 3D forms layer-by-layer. Parts can be made cheaper, faster, and in shapes that are impossible to create with conventional manufacturing. The layer-by-layer nature of the building process means there’s no need for tool access into small areas, giving designers almost complete geometric freedom, and the rapid production times make additively manufactured parts attractive to the space community.
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Aerospace scientists prepare to quench metal samples during the heat treatment of Ni-based superalloys.
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Manufacturing components for space is an unforgiving process, requiring flawless reliability in the extremely harsh space environment. Additive manufacturing is a new process, and the full scope of the relationships between the manufacturing processes, component microstructures, and part performance is not yet fully understood. This is why Aerospace has come in on the ground level, using our own machines and analytical capabilities to learn more about the technologies and their limitations, and be able to provide world-class expertise based on our own experience and research.
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Rapid metal printing enables the aerospace industry to produce highly complex and monolithic parts for flight hardware.  The use of a moving energy source—in this case a laser—to build up components layer-by-layer eliminates geometrical constraints related to traditional machining.  Each layer consists of a thin application of fresh powder followed by localized melting of these particles. This video showcases the formation of a single layer of the Physical Science Laboratories and Aerospace logos. Rapid melting and solidification occur as the 50 µm diameter heat source rasters across the surface at 1 m/s, leaving a molten trail in its wake.
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This 3D printer is capable of making parts out of certain types of metals like:
• Inconel 718, a nickel alloy
• Invar, a nickel-iron alloy notable for its lack of expansion or contraction with changes in temperature
• Several types of aluminum alloys
The printer uses a technique called Selective Laser Melting (SLM) to create these parts one layer at a time.
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This 3D printer uses a process called fused deposition modeling (FDM) to extrude molten polymer into organized patterns that comprise a single layer. This process repeats itself over and over again, fusing extruded beads of material to adjacent deposits as well as to the layer below until the net-shape has been formed. As additive manufacturing technology advances, stronger and more durable engineering thermoplastics have become available, such as the ULTEM 9085 shown here.
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Welcome to the Additive Manufacturing Laboratory. Aerospace has been a leader in additive manufacturing since 2012. We combine our hands-on manufacturing experience with materials science expertise and component characterization capabilities to understand the relationship between the manufacturing process and the part performance. We can study the microstructures that are unique to additively manufactured parts, which lets us engineer unique solutions like composite replicated optics and innovative antenna structures.
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Welcome to the Additive Manufacturing Laboratory. Aerospace has been a leader in additive manufacturing since 2012. We combine our hands-on manufacturing experience with materials science expertise and component characterization capabilities to understand the relationship between the manufacturing process and the part performance. We can study the microstructures that are unique to additively manufactured parts, which lets us engineer unique solutions like composite replicated optics and innovative antenna structures.
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The Aerospace Corporation
www.aero.org
John Binkley
SYSTEMS DIRECTOR
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The Aerospace Corporation
www.aero.org
John Binkley
SYSTEMS DIRECTOR
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