Autodesk has partnered with a Michigan foundry in a 3D printing proof-of-concept challenge that resulted in a new magnesium commercial airline seat frame so mild it may save an airline greater than $200 million in gasoline prices.
Autodesk used its Netfabb 3D design software to supply a fancy geometric mannequin for a brand new plane passenger seat body simply as robust as a conventional seat, however vastly lighter.
The CAD program created a file used to 3D print in plastic the seat body, which was then coated in ceramic materials and heated to a excessive temperature to evaporate the inside plastic.
The remaining ceramic mould was then utilized by Aristo Cast, a Michigan foundry, to fabricate a magnesium seat body that weighs 766 grams, 56% lighter than the traditional 1,672-gram aluminum seats in use at this time.
Whereas laser sintering, one other 3D printing methodology, presents the power to create objects with dozens of metals, it’s sluggish in comparison with metallic casting, which may use 1000’s of metals or composite supplies.
Moreover, 3D printing is restricted to the comparatively small measurement of a print beds – just a few toes in measurement — even in business machines. Conventional metallic casting has practically limitless manufacturing scalability.
With the ensuing ceramic mould, Aristo Forged confirmed it may make as much as 160 of the magnesium airplane seats each two days.
Autodesk and Aristo Forged declare that if an plane maker corresponding to Airbus had been to switch all 615 seats on its A380 jets with the brand new, lighter magnesium seat frames — throughout a fleet of 100 planes which usually have a 20-year lifespan — the transfer would save $206 million, primarily based on common jet gasoline prices in 2015. Together with decreasing gasoline prices, the brand new seats may additionally imply 126,000 fewer tons of C02 emissions if used on a single mannequin plane.
“Whereas additive manufacturing holds nice promise for the way forward for manufacturing, it is nonetheless very new for a lot of product builders. Casting, against this, has been round for millennia and is extremely properly understood,” Autodesk analysis scientist Andreas Bastian mentioned in an announcement. “There are tons of of 1000’s of engineers, foundries, and factories with deep experience in it. That is one of many causes I’m in search of a bridge between the 2.”
For the previous yr, Bastian has been working at Autodesk’s 27,000-square-foot expertise heart in San Francisco to supply the lighter airline seat. Bastian used the algorithms within the Netfabb 3D design software program to create an intricate latticework that resulted in a seat simply as robust.
“We leapt on the alternative to work with Andreas and Autodesk. It is an thrilling challenge and allowed us to pioneer some new strategies for magnesium casting,” Paul Leonard, Aristo Forged’s chief engineer, mentioned in an announcement. “It additionally gave us an opportunity to be taught extra about superior design and optimization strategies. That is nonetheless fairly new in our business.”
Whereas a breakthrough for airline seat frames, what Autodesk and Aristo Forged is analogous to what’s being examined in different industries.
Ford Motor Co., for instance, has been utilizing a myriad of 3D printing technologies to fabricate working prototypes for automobile and truck components.
The carmaker has 5 3D prototyping facilities, three within the U.S. and two in Europe. At its Dearborn Heights, Mich. facility, 14 completely different industrial 3D printers prove 20,000 components a yr. A single print run on one machine can create anyplace from a number of components to tons of.
One 3D printing methodology, known as binder jet printing, lays down layer upon layer of sand. Every successive layer of sand is sure to the final with adhesives to create a mould for making metallic prototype components that used to take as much as 10 weeks to create utilizing standard molds.
In the present day, utilizing binder jet printing, prototype molds can be utilized to supply tons of of molds on a single machine in a couple of week.
One other methodology in use at Ford is laser-sintering, the place a number of machines carry out fast prototyping of components by melting tons of to 1000’s of successive layers of positive silica collectively. What emerges from the printer is an amorphous block of powdered silica from which dozens of hardened components are eliminated by hand and cleaned with a brush and vacuum.
What can be distinctive about Autodesk and Aristo Forged’s proof-of-concept challenge is that they not solely decreased an airline seat weight with a extra refined body design, however they had been capable of forged in magnesium — no easy activity.
Sometimes, aluminum is used for airplane seats, however magnesium is 35% lighter. Autodesk’s 3D design optimization resulted in additional than half of the load discount and the magnesium accounted for the remainder, Autodesk claims.
For Aristo Forged, combining a more recent expertise like 3D printing with confirmed metallic casting strategies may spur new progress in its business.
“We have seen so much foundries in our area shutter their doorways lately as manufacturing strikes abroad,” Aristo Forged’s CEO, Jack Ziemba, mentioned in an announcement. “We see adopting new strategies like additive manufacturing, even when blended with our experience in casting, as a means ahead — not only for our firm however for plenty of different foundries within the Midwest.”