Focus on 3D Printing for Aerospace Applications Discussed at TCT 3Sixty

At the TCT 3Sixty 2024 event, key figures from ITP Aero and GKN Aerospace delved into the transformative potential of 3D printing for aerospace applications. Through captivating presentations, Sarah Everton from ITP Aero underscored the substantial benefits of Design for additive manufacturing, showcasing real-world cases like the laser powder bed fusion technique used for the Rolls-Royce UltraFan Program, which impressively cut down energy and material usage by 25%. On the other hand, Liam Pang from GKN Aerospace highlighted the promising reductions in material waste and CO2 emissions achieved through additive manufacturing but pointed out the critical need for sector-wide collaboration to overcome certification and qualification hurdles. Both highlighted that while the future holds immense potential, addressing skill gaps and improving productivity within 3D printing are pivotal for the industry’s sustainable and efficient advancement. Have you ever wondered how 3D printing is revolutionizing the aerospace industry? If so, you’re in the right place! Let’s dive into the fascinating world of 3D printing for aerospace applications, discussed extensively at this year’s TCT 3Sixty event.

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Event Overview

This year’s tct 3sixty, held in 2024, was a hub of discussions centering around the applications of 3D printing in the aerospace industry. Keynote speakers from major players like ITP Aero and GKN Aerospace took the stage to share their insights, offer real-world examples, and discuss future challenges and opportunities.

Focus on 3D Printing for Aerospace

This year’s focus was firmly set on 3D printing for aerospace. Both keynote speakers and attendees explored its transformative potential, examining how it’s shaping the future of aircraft manufacturing and maintenance.

Keynote Speakers

The event featured enlightening discussions by Sarah Everton, a Manufacturing Engineer from ITP Aero, and Liam Pang, a Senior Research Engineer from GKN Aerospace. Their presentations highlighted the significant strides their companies have achieved through additive manufacturing (AM).

ITP Aero: A Deep Dive

Introduction by Sarah Everton

Sarah Everton from ITP Aero captivated the audience with her presentation, emphasizing the benefits of Design for Additive Manufacturing (DfAM). She showcased how 3d printing, particularly laser powder bed fusion (LPBF), is being used to overcome traditional manufacturing limitations.

Real-World Case Studies

Sarah brought the discussion to life by highlighting real-world examples of how ITP Aero has leveraged 3D printing to achieve tangible benefits. She discussed projects like the Rolls-Royce UltraFan Program, where LPBF has drastically reduced both energy and material requirements.

Project	Technology Used	Benefits
Rolls-Royce UltraFan Program	Laser Powder Bed Fusion (LPBF)	Reduced energy and material requirements by 25%
Tail-Bearing Housing	3D Printing	Lowered noise and emissions in aircraft engines

Benefits of 3D Printing in Aerospace

A major highlight of Sarah’s presentation was the focus on benefits like weight, time, and cost savings. She elaborated on how 3D printing enables the production of lighter components without sacrificing strength, thus reducing fuel consumption and emissions.

Energizing Innovations

One standout example is the 3D printed tail-bearing housing structure used in aircraft engines. This innovation not only reduces noise and emissions but also illustrates the broader sustainability benefits 3D printing can offer.

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GKN Aerospace: Insights and Challenges

Presentation by Liam Pang

Liam Pang from GKN Aerospace provided a comprehensive look at the advantages and barriers associated with 3D printing in aerospace. His presentation underscored the complexities of certification and qualification, as well as the need for widespread collaboration within the industry.

Certification and Qualification Issues

Liam was candid about the hurdles presented by certification and qualification processes. He stressed that industry-wide standards are crucial for advancing 3D printing technologies.

Material Waste Reduction

One of GKN Aerospace’s remarkable achievements is the use of additive manufacturing to significantly reduce material waste and CO2 emissions. Liam showcased a large-scale aircraft engine component where material waste was slashed by a stunning 90%.

Innovation	Outcome
Large-Scale Engine Component	Reduced material waste by 90%
Various Components	Lowered CO2 emissions significantly

Collaboration for Better Results

A crucial takeaway from Liam’s talk was the importance of collaboration across the sector. He emphasized that for 3D printing to reach its full potential, stakeholders must work together to overcome existing barriers.

Future and Challenges

The road ahead for 3D printing in aerospace is paved with opportunities, but it’s not without challenges. Both keynote speakers highlighted the importance of industry collaboration, improved productivity, and tailored education on DfAM.

Importance of Industry Collaboration

Collaboration is key to overcoming certification challenges and fostering innovation. Establishing standardized guidelines will streamline processes and enhance the overall adoption of 3D printing technologies in aerospace.

Need for Improved Productivity

Increased productivity in 3D printing is necessary to meet the growing demands of the aerospace sector. Speakers emphasized the need for more efficient and faster printing methods to stay competitive.

Education and Skill Gaps

Identifying and addressing skill gaps in 3D printing technology is crucial. Continued education and training programs tailored to DfAM will ensure that the industry is equipped with knowledgeable professionals.

Industry Impact

The presentations from ITP Aero and GKN Aerospace collectively demonstrated significant material and cost savings. Their focus on sustainable and efficient manufacturing processes highlighted the broader impact these innovations have on the industry.

Material and Cost Savings

Both companies showcased projects where material and cost savings were substantial. These examples illustrate how 3D printing can drive economic and environmental benefits.

Sustainable Manufacturing

Sustainability was a recurring theme throughout the event. The case studies presented highlighted how 3D printing is paving the way for more sustainable aerospace manufacturing processes.

Cross-Sector and Technology Collaboration

The event underscored the importance of cross-sector and technological collaboration. By sharing best practices and working together, the industry can collectively overcome barriers and accelerate the adoption of 3D printing.

Next Steps

Looking ahead, there’s a clear path for continued development and application of 3D printing in aerospace. The industry’s focus should remain on collaboration, innovation, and education to fully realize the potential of these transformative technologies.

Register for Upcoming Events

To stay ahead of the curve, consider registering for the upcoming AMAA 2024 event, where industry insights and the latest advancements in additive manufacturing will be discussed in detail.

Continued Development and Application

The journey of 3D printing in aerospace is just beginning. Ongoing development and application of these technologies will pave the way for a more efficient and sustainable aviation industry.

By focusing on these key areas, the aerospace sector can harness the full potential of 3D printing, driving innovation and sustainability for years to come.

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