A Review of Additive Manufacturing (3D Printing) in Aerospace: Technology, Materials, Applications, and Challenges

Fu, XinXin; Lin, YuXuan; Yue, Xue-Jie; XunMa,; Hur, Boyoung; Yue, Xue-Zheng

doi:10.1007/978-3-030-98671-1_6

Cited by 9 publications

(3 citation statements)

References 89 publications

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“…In Industry 4.0, 3D printing will likely drive a more sustainable, digitalized, and resilient future [9,10]. The advent of 3D printing technology has revolutionized various industries, including healthcare, biomedical, aerospace, energy, water puri-fication processes, consumer products, and food, presenting novel opportunities for innovation and efficiency [11][12][13][14]. However, its integration into mainstream applications remains challenging due to quality, reliability, standardization, material limitation, and high cost underscoring the need for extensive research in this field [15,16].…”

Section: Introductionmentioning

confidence: 99%

Advancing 3D Printing through Integration of Machine Learning with Algae‐Based Biopolymers

Bin Abu Sofian,

Lim,

Chew

et al. 2024

ChemBioEng Reviews

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The integration of machine learning (ML) with algae‐derived biopolymers in 3D printing is a burgeoning area with the potential to revolutionize various industries. This review article delves into the challenges and advancements in this field, starting with the critical problem it addresses the need for sustainable and efficient additive manufacturing processes. Algae‐based biopolymers, such as alginate and carrageenan, are explored for their viability in 3D printing, highlighting their environmental benefits and technical challenges. The role of ML in enhancing material selection, predictive modeling, and quality control is examined, showcasing how this synergy leads to significant improvements in 3D printing processes. Key findings include the enhanced mechanical properties of algae‐based biopolymers and the optimization of printing parameters through ML algorithms. Examples like the use of Spirulina in creating a range of materials and the application of carrageenan in bone tissue engineering are discussed. The conclusion underscores the transformative impact of combining ML with algae‐based biopolymers in 3D printing, paving the way for innovative, sustainable solutions in additive manufacturing. Despite existing challenges, this integration holds promise for a future of advanced, eco‐friendly manufacturing techniques.

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Section: Introductionmentioning

confidence: 99%

Advancing 3D Printing through Integration of Machine Learning with Algae‐Based Biopolymers

Bin Abu Sofian,

Lim,

Chew

et al. 2024

ChemBioEng Reviews

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“…The profound impact of this method on the aerospace sector can be attributed to its unique ability to produce parts layer by layer, thereby transforming the traditional paradigm of component manufacturing and design. [1,2] This inherent flexibility fits seamlessly with the aerospace industry's need to reduce the mass, material consumption and cost of components while maintaining essential mechanical properties [1,2,3]. These components are typically made from high strength superalloys such as Inconel 718 (IN718), which are designed to withstand harsh operating conditions throughout their service life.…”

Section: Introductionmentioning

confidence: 99%

Holistic view of additive manufacturing of blade integrated disks in the context of aerospace certification

Boseila,

Schneider,

Ganser

et al. 2024

Laser 3D Manufacturing XI

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The production of safety class 1 blade integrated disks (blisks) traditionally involves costly and time-consuming methods, utilizing precision machining of a solid forged block of nickel-based alloy in compliance with DIN EN 9133. This conventional approach, while meeting stringent certification requirements for turbine components operating under extreme conditions (900-1400°C), suffers from increased tool wear due to milling solid blocks, leading to design limitations impacting efficiency. In this context, layer-by-layer construction using additive manufacturing (AM) processes, such as laser-based powder bed fusion of metals (PBF-LB/M), enable a resource-efficient process with a high level of design freedom. Process-related support structures typical for the PBF-LB/M process must be subsequently separated using subtractive processes, whereby the synergy and implications of integrating additive and subtractive manufacturing on the certification process has been insufficiently researched. The component properties of PBF-LB/M components exhibit greater deviations compared to conventional manufacturing methods as a result of local remelting and the associated complex temperature fields, complex machine transferability and reproducibility. In this work, the integration of additive manufacturing into the existing process chain was investigated. Considering the aerospace certification of safety class 1 components, a holistic process chain from the digital component model to the finished part was developed, which consists of design definition, additive manufacturing, heat treatment, subtractive post-processing and referencing as well as quality assurance along the entire process chain. We investigated the interdependencies of the various work steps in the process chain and the transfer of certification requirements in accordance with the conventional production route. The divergence in input material (powder), data preparation methods (support structures), machine maintenance, manufacturing complexity (dimensional accuracy), and component properties (reproducibility) poses significant challenges in applying established standards. Additionally, the absence of regulatory guidelines within the aerospace sector and specific OEM directives for additive manufacturing complicates the comprehensive evaluation of the alternative approach proposed. A better understanding of the complex interplay of various factors impacting additive manufacturing is crucial to promote OEM acceptance. However, due to this complexity, a final validation requires the integration of OEMs and the official institutes such as DIN, ISO, ASTM and EN to assess and create alternative standards. The combination of additive manufacturing and subtractive manufacturing may change the nature of BLISK manufacturing for aerospace in the near future, ensuring high-performance and efficient aviation.

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“…One of the possible solutions to prevent these negative effects is the usage of advantageous 3D-printed composites with better resistance to dilatation (Dou et al , 2020) in a wide range of temperatures (Feng and Yang, 2018; Le Riche and Gaudin, 1998). Such 3D-printed composites have already been considered promising in aircraft, rocket and space technologies (Kalsoom et al , 2016; Fu et al , 2022; Velu et al , 2019).…”

Section: Introductionmentioning

confidence: 99%

3D composite printing: study of carbon fiber incorporation to different construction thermoplastic matrices in regard to dilatation characteristics

Dvorak,

Zarybnicka,

Ševčík

et al. 2024

RPJ

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Purpose The purpose of this paper is to clarify the relationship between the use of different polymer matrices for the preparation of composite materials, namely, polyethylene terephthalate-glycol (PET-G) and polyamide (PA), using Composite Fiber Co-Extrusion technology with the application of two types of carbon fibers, short and continuous. The aim of the study is also to extend the knowledge of the production of composite materials with a defined structure from the point of view of their influence on the microstructure and their physical-mechanical properties. Design/methodology/approach As part of the experiment, four types of samples were prepared, namely, two types of samples with PA polymer matrix and two types with PET-G polymer matrix. All types contained short carbon fibers and always one set from each polymer matrix in addition to continuous carbon fibers. All types were prepared using the same 3D printing parameters to avoid any further influence. The samples were then tested for microstructure using microCT, mechanical properties using a tensile test and dilatation characteristics from the point of view of aerospace applications. Finally, the raw materials themselves were tested. Findings The paper provides insight into the influence of polymer matrix types on the physico-mechanical properties of 3D printed composites. The analysis confirmed that the physico-mechanical results varied with respect to the interface between the polymer matrix and the carbon fiber. The implications of the conclusions can be extended to the development of products in the aerospace and automotive sectors. Originality/value This study provides information for composite applications in the aerospace industry, focusing on evaluating dilatation characteristics within very low temperatures (−60 °C) when using carbon fibers (continuous carbon fibers, short carbon fibers and a combination of both) in two types of thermoplastic matrices. This perspective on materials characterisation for aerospace applications is a very important and unpublished approach within the 3D printing of composites. These characteristics are important parameters in the design of prototypes and functional samples with regard to the resulting behaviour in real conditions.

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A Review of Additive Manufacturing (3D Printing) in Aerospace: Technology, Materials, Applications, and Challenges

Cited by 9 publications

References 89 publications

Advancing 3D Printing through Integration of Machine Learning with Algae‐Based Biopolymers

Advancing 3D Printing through Integration of Machine Learning with Algae‐Based Biopolymers

Holistic view of additive manufacturing of blade integrated disks in the context of aerospace certification

3D composite printing: study of carbon fiber incorporation to different construction thermoplastic matrices in regard to dilatation characteristics

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