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Preliminary Investigation into the Influence of 3D Printing on Sustainable Manufacturing Carter Keough, Ola Harrysson, Ron Aman, Harvey West, Russell King, Tim Horn
Case Study 1: Utilization of Raw Materials
Using Computer Assisted Design(CAD) software several
aerospace parts were analyzed and redesigned for additive
manufacturing to minimize material subject to satisfying
physical and structural constraints.
Case Study 3: Point of Use Manufacturing
Preliminary data suggest the validity of the original
hypotheses. Additive manufacturing has the potential to
greatly reduce material waste and to realize downstream fuel
savings associated with reduced weight. To fully understand
the impact of additive manufacturing on the supply chain
more research is required. For future studies more accurate
costs of individual product infrastructures will be calculated,
including the costs of tooling, handling and shipping, etc.
Mass Savings of Flying Part: 2.88 lb.
Ti6Al4V NNS Part for EBM:
Mass of Stock = 4.67 lb.
Vol.= 29.20 𝑖𝑛3
Mass of Final Part= 4.67 lb.
Waste = 0.2 lb.
B2F = 1.04
Ti6Al4V Stock for Machining:
Mass of Stock = 23.43 lb.
Vol. = 146.43 𝑖𝑛3
Mass of Final Part =4.67 lb.
Waste = 18.76 lb.
B2F = 5.02
Abstract
From the standpoint of sustainability, additive manufacturing
has the potential to profoundly reduce our reliability on fuel, raw
materials and, to mitigate our impact on the environment.
however the magnitude of these benefits has not been quantified
and, design guidelines have not been established.
Preliminary research has identified 3 key hypotheses for further
investigation:
1. Savings in raw materials: Additive manufacturing is a tool-
less near net shape(NNS) process and, material is only used
where it is needed.
2. Savings in weight: Additive manufacturing facilitates the
design and use of complex geometries not feasible using
traditional manufacturing. For high volume aerospace
components this translates directly to a reduced reliance on
fossil fuels.
3. Savings in the supply chain: Additive manufacturing has the
potential to eliminate the need for part specific tooling and
reduces the reliance on the factory/mass production system.
This in turn facilitates point of use
manufacturing, which reduces fuel
consumption and costs associated with
shipping, inventory and transport.
Background
3D Printing or, Additive Manufacturing is a relatively new
process of directly fabricating parts from computer models by
consolidating, curing, or depositing successive layers of raw
materials. Initially, this technology was used for
the rapid fabrication of plastic
prototypes.
Recently, electron beam melting (EBM),
developed by Arcam, is one such process
in which a high powered electron beam,
controlled by electromagnetic coils, is
generated to selectively melt together
layers of metal powders, facilitating
the manufacture of fully dense metal
parts.
Original Aerospace Part: Ti6Al4V, hot
gas manifold.
Buy-To-Fly (B2F) Ratio: The mass of
the material required to manufacture a
part divided by the mass of the final
part that flies on the airplane
Arcam A2 EBM System in the NCSU Department of Industrial and Systems Engineering
Methods
0
50
100
150
200
250
300
Ti-6Al-4V Inconel 625 6061 Al
Raw
Mat
eri
al C
ost
(U
SD)
Machined ComponentNNS ComponentRedesigned Component
High performance alloys
used for aerospace
applications (Ti-6Al-4V,
Inconel 625, etc.) are
typically associated with
high prices. Machining of
chips from a billet is not
efficient or economical
for many of these
materials.
Case Study 2: Reducing Weight
The design of structural aerospace components often involves
making tradeoffs between conflicting objectives. Reduced
weight in one or more components can significantly improve
the fuel carrying capacity, range, and maneuverability of the
structure.
Additive manufacturing
technologies facilitate the
production of non-stochastic
structures in a wide variety of
materials with geometries that
can be optimized for a given
set of constraints
1st Iteration 4.67 lb 2nd Iteration 1.37 lb 3rd Iteration 1.79 lb
Many optimization criteria can be used but weight reduction while
maintaining a specified stiffness, strength or displacement is a
very common goal. According to a recent Boeing study1, for a 777
on a 5000 mile journey, each additional pound of weight requires
an additional 0.4 lbs of fuel. With 1113 aircraft this equates to an
approximate annual 680 klbs of fuel savings (an annual
reduction in atmospheric CO2 emissions of 2.1 x 106 lbs)
1 http://www.boeing.com/commercial/airports/acaps/777sec3.pdf .
Conclusions:
The case of legacy parts and aging aircraft
illustrates the effectiveness of tool-less
manufacturing.
Consider a Ti6Al4V C130 Hinge Component
The original was wrought (forged) however it
is no longer available from the OEM. The
lead time on a new forging die was
determined from industrial partners to be
about 18-24 months at a cost of $60K-$100K
With EBM, the hinge part was produced in Ti6Al4V with
wrought properties (exceeding ASTM F1472) in 22 hours at a
cost of roughly $2.5K. This reduces the need to
transport/store spare parts, these results could have a
significant impact on naval , air and space activities.
For more information on this and other projects, visit The Laboratory for Additive Manufacturing and Logistics:
http://camal.ncsu.edu/
This work is partially funded by the National Science Foundation NSF An ARK on the SEE: Sustainability, Energy & the Environment REU #0935161
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