NIAR Purchases Sapphire 1MZ to Enhance Aerospace AM

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Have you ever wondered how groundbreaking advancements in aerospace manufacturing come to life? The National Institute for Aviation Research (NIAR) is at the forefront of this innovation. Recently, they acquired the Sapphire 1MZ printer from Velo3D, a leading metal additive manufacturing (AM) technology company. This move is set to revolutionize how metal 3D printed parts are qualified for airframe applications. Let’s delve into the details of this exciting acquisition and explore its wider impact on aerospace additive manufacturing.

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The New Acquisition: Sapphire 1MZ from Velo3D

What is the Sapphire 1MZ?

The Sapphire 1MZ is an advanced metal 3D printer developed by Velo3D. With a 315Ø x 1000mm build envelope, this machine is designed to produce large and complex parts. One of its standout features is its capacity to work with Inconel 718, a nickel-based superalloy known for its high resistance to corrosion, oxidation, and creep at extreme temperatures. These attributes make it a crucial material for aerospace applications.

Why Inconel 718?

In the world of aerospace, Inconel 718 is not just a material; it’s a game-changer. This nickel-based alloy excels in high-temperature environments, making it perfect for jet engines and other aerospace components that must endure extreme conditions. By leveraging the capabilities of Sapphire 1MZ, NIAR aims to push the boundaries of what’s possible in airframe design and manufacturing.

NIAR’s Mission and Vision

Who is NIAR?

The National Institute for Aviation Research (NIAR) was established in 1985 at Wichita State University. With a $350 million annual budget, a staff of 1,200, and locations in Wichita, Kansas, and Huntsville, Alabama, NIAR has grown into a powerhouse of aeronautical research and innovation. They’re heavily involved in federal resources and programs aimed at advancing aerospace and defense industries.

The Purpose Behind the Acquisition

NIAR’s team seeks to identify new materials, designs, and manufacturing techniques to bolster America’s aerospace, defense, and manufacturing sectors. Partnering with Velo3D helps them better understand additive manufacturing processes, enabling them to build confidence in 3D printed parts. This, in turn, accelerates the adoption of advanced manufacturing technologies in these critical sectors.

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The Importance of Performance-Based Qualification

Addressing a Pressing Challenge

Qualifying 3D printed parts for production use has been a significant obstacle in the broader adoption of additive manufacturing, particularly in commercial aviation applications. Traditional qualification methods are often inadequate for the unique challenges posed by 3D printing. Therefore, NIAR’s research into performance-based qualification methods will be invaluable.

Best Practices and Validation

The Sapphire 1MZ will help NIAR identify and validate best practices for qualifying additively manufactured parts. This involves exhaustive testing and analysis to ensure that the parts meet the rigorous safety and performance standards required for airframe applications. Essentially, NIAR is on the verge of setting new industry standards.

Funding and Broader Research

Financial Backing from FAA and NASA

NIAR recently received substantial financial backing to further their research: $10 million from the Federal Aviation Administration (FAA) Center of Excellence for Composites and Advanced Materials (CECAM) and another $10 million from NASA. These funds will support the development and implementation of advanced materials like composites and metal AM for hypersonic and other advanced aerospace applications.

The Role of FAA CECAM

Established in 2004 in partnership with the FAA and NIAR, the Center of Excellence focuses on pioneering research in advanced materials, including composites and additive manufacturing. The new funding will enable further groundbreaking research, potentially transforming entire segments of the aerospace industry.

Velo3D and the Assure Quality Assurance Software

Assure: Comprehensive Quality Assurance

One of the cornerstones of this partnership is Velo3D’s Assure Quality Assurance software. This tool collects data on each layer of a print, giving engineers complete confidence in their parts. From capturing images of each layer to comparing these datasets against existing ones, Assure ensures consistency and quality.

Impact on Performance-Based Qualification

Assure plays a pivotal role in NIAR’s performance-based qualification research. By providing in-depth, layer-by-layer data, the software enables NIAR to ensure that the manufactured parts are consistent and reliable, which is crucial for airframe applications.

The Wider Implications for Aerospace Additive Manufacturing

Accelerating Adoption

This collaboration aims to eliminate one of the most significant barriers to the broader adoption of additive manufacturing in aerospace: the qualification of 3D printed parts. By developing robust performance-based qualification methods, NIAR and Velo3D are paving the way for more widespread use of AM in aerospace.

Key Challenges and Opportunities

Qualifying 3D printed parts is fraught with challenges. Traditional methods often fall short, and new, more rigorous approaches are needed. NIAR’s work, supported by Velo3D’s technology, aims to address these challenges head-on. The potential benefits are immense, from reducing costs to improving performance and accelerating the development of new aerospace components.

Conclusion

The acquisition of the Sapphire 1MZ by NIAR represents a significant milestone in the field of aerospace additive manufacturing. With the backing of Velo3D’s advanced technology and comprehensive quality assurance software, NIAR is poised to develop new standards and best practices for the qualification of 3D printed parts. This groundbreaking research will not only benefit NIAR but has the potential to revolutionize the entire aerospace industry. You are now part of this exciting journey into the future of aerospace manufacturing.

Are you ready to see how these advancements will reshape the skies?

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