The New Shop Class connects the worlds of the maker and hacker with that of the scientist and engineer.
If you are a parent or educator or a budding maker yourself, and you feel overwhelmed with all of the possible technologies, this book will get you started with clear discussions of what open source technologies like 3D Printers can really do in the right hands.
Written by real "rocket scientist"Joan Horvath, author of Mastering 3D Printing, and 3D Printing expert Rich Cameron, The New Shop Class is a friendly, down-to-earth chat about how hands-on making things can lead to a science career.
Get practical suggestions about how to use technologies like 3D printing, Arduino, and simple electronics. Learn how to stay a step ahead of the young makers in your life and how to encourage them in maker activities. Discover how engineers and scientists got their start, and how their mindsets mirror that of the maker.
Additive Manufacturing or 3D Printing has a great potential to develop significant advances in materials, printers’ technology, and processes.
Thus, the layer by layer manufacturing has existed for three decades and new developments recently appeared in smart materials.
Laboratories discovered ways to design and manufacture advanced structured materials and responsive materials used in multi-functional and high-performance products.
The current research and development efforts will have an impact on the traditional design and manufacturing process. 4D Printing announces a major modification in the product design and manufacturing process from static structures to dynamic structures like Shape Memory Material (SMM) with integrated functionalities.
This article presents a review of smart materials based on a classification of advanced structured materials and responsive materials before beginning a description of current applications. The use of multi-materials and the study of predictive models to simulate the responsive materials behaviour accelerate the smart materials development.
The paper is concerned with design, analysis and fabrication of the small size Unmanned Aerial Vehicle composite frame structure.
The frame has the form of a lattice composite structure manufactured by 3D printing of continuous carbon fibers and two matrix materials – thermoset, which is used to join the elementary fibers in the tow, and thermoplastic, which consolidates the cured tows into a unidirectional composite.
The paper consists of contains the description of the 3D printing procedure, finite element analysis of the structure, test results for mechanical properties of the structural elements and the fabricated frame. The result of analysis is in good agreement with experimental data.
Wind tunnel testing is a reliable means for aircraft design. The wind tunnel models are the objects used in the tests. The accuracy and economy of the model design and fabrication have an important impact on the quality and cycle of aircraft development. Additive Manufacturing (AM, or Rapid Prototyping, 3D printing) can directly fabricate 3D parts through accumulating raw materials, and is widely regarded as a revolutionary advancement in manufacturing technology.
In the very early development period, AM was soon introduced and was studied by many groups worldwide. Firstly, the introduction of AM is an advancement for the fabrication of models, which can greatly improve the fabrication economy of current models, such as reducing the number of parts, and shortening the processing cycle etc. Secondly, the introduction of AM can also improve the design of models, which is helpful to develop new types of models and even new test methods. Thirdly, AM has blurred the boundaries between real aircraft and experimental models, and promoted the development of new concept aircraft.
The review first introduces the design requirements of the wind tunnel test models and recalls the AM application history for models. Next, detailed technologies concerning the design procedure and fabrication processing of the AM-based models are presented. Finally, the application of AM-based model in the development of current air vehicles and new-concept vehicles is introduced. The review provides an overview of techniques of AM in wind tunnel test models, and provide typical examples for reference to designers and researchers in the aerospace industry.
After reading the title of this post, you may be thinking that the Super Discovery is merely a very large version of a standard 3D Production System.
Well, this is not the case: Some of the Super Discovery’s specifications are a bit unusual for 3D Production Systems. The minimum layer size, for example, is 0.5 mm, which may be perhaps not surprising. But the largest possible layer size, one that might be used when 3D printing large items, is 10 mm.
The manufacturer has installed a hot end that is capable of hitting an astonishing 450 ºC, making the Super Discovery able to attempt 3D printing of many strong engineering materials... in huge sizes. Their high-performance material capability is extremely interesting because it opens up the possibility of 3D Printing large production components for militaryUAVs, among other applications.
This enormous 3D printer that uses pellets as input material, is developed and produced in Spain by a company that began developing 3D Printing technology five years ago. Prior to that, and still occurring, is their marketing of other manufacturing equipment, including CNCs, lasers, and the like.
What is the price of this massive machine? Well, it depends, because each machine is custom built. But you will find more info at:
Dramatic improvements in robotics, artificial intelligence, additive manufacturing (also known as 3D printing), and nanoenergetics are dramatically changing the character of conflict in all domains.
In the last few years, additive manufacturing, also known as 3D printing, has gone from an interesting hobby to an industry producing a wide range of products from an ever-growing list of materials: The global explosion of additive manufacturing means it is virtually impossible to provide an up-to-date list of materials that can be printed, but the top-4-most-wanted list for the military industry would include metals, thermoplastics, composites and ceramics.
In addition to a wide range of materials, additive manufacturing has gone from being able to make only a few prototypes to being able to produce parts in large or very large formats. At the same time, additive manufacturingis dramatically increasing the complexity of objects it can produce, while simultaneously improving speed and precision.
As the affordability, reliability and ease-of-use of Unmanned Aerial Vehicles (UAV) advances, the use of aerial surveying for cultural heritage purposes becomes a popular choice, yielding an unprecedented volume of high-resolution, geo-tagged image-sets of historical sites from above.
As well, recent developments in photogrammetry technology provide a simple and cost-effective method of generating relatively accurate 3D models from 2D images. These techniques provide a set of new tools for archaeologists and cultural heritage experts to capture, store, process, share, visualise and annotate 3D models in the field.
This paper focuses on the methodology used to document the cultural heritage site of Asinou Church in Cyprus using various state of the art techniques, such as UAV, photogrammetry and 3D printing. Hundreds of images of the Asinou Church were taken by a UAV with an attached high resolution, low cost camera. These photographic images were then used to create a digital 3D model and a 3D printer was used to create a physical model of the church.
Such a methodology provides archaeologists and cultural heritage experts a simple and cost-effective method of generating relatively accurate 3D models from 2D images of cultural heritage sites.
Additive Manufacturing (AM, or 3D printing) is an emerging manufacturing technology with far-reaching implications: AM is increasingly used to produce functional parts, including components for safety-critical systems, but its unique capabilities and dependence on computerization raise a concern that an AMgenerated part could be sabotaged by a cyber-physical attack.
In this paper, it is demonstrated the validity of this concern by presenting a novel attack: reducing the fatigue life of a 3D-printed quadcopter propeller, causing its mid-flight failure, ultimately leading to the quadcopter’s fall and destruction.
The purpose of this paper is to present the benefits offered by Rapid Prototyping (RP) models for wind‐tunnel testing as part of fourth‐year aerospace engineering student projects.
Ways of overcoming some of the difficulties associated with the 3D Printing Technology are also discussed.
Hexadrone's Tundra-MUAV is showcased at Eurosatory 2018, Paris Nord Villepinte, booth F528 Hall 6. The event is held from June 11th to June 15th. It is the first 100% customizable UAV for users specialized in defense and rescue.
The UAV’s body and arms have been manufactured in Windform® SP (body) and Windform® XT 2.0 (arms). The rapidly detachable arms and three quick release attaches make the Tundra-M extremely flexible to meet the needs of any profession, while making operational conditions easier to maintain.
Tundra-M is Hexadrone’s first fully modular and easy-to-use UAV for industrial and multi-purpose tasks, made for extreme weather conditions thanks to rugged, waterproof design. Tundra-M is the most advanced professional UAV created by Hexadrone.
Tundra-M3D printed functional prototype has been manufactured by CRP Technology via professional 3D printing using Windform® Carbon-composite materials. Windform® XT 2.0 and Windform® SP are Carbon-fiber reinforced composite 3D printing materials from Windform family of high performance materials.
Windform was created by CRP Technology, CRP Group’s specialized company in advanced 3D printing and additive manufacturing solutions.
Defense companies are using 3D Printing more often today to build parts for weapons: Aerojet Rocketdyne is using the technology to build rocket engines, Huntington Ingalls is using it to build warships and Boeing is 3D printing parts for its commercial, defense, and space products.
"Someday, the military will 3D-print missiles as needed" says Will Roper, the U.S. Air Force’s acquisition chief. In the shorter term, he just wants to use Additive Manufacturing Technology to get broken planes back in the air. But there is a legal, not technical, roadblock: Today’s 3D-printers could make short work of part deliveries, but some of those parts’ original manufacturers control the intellectual property — and so far, the service lacks clear policy for dealing with that.
Researchers have now demonstrated and exposed in the paper "Additive Manufacturing of an iron-based bulk metallic glass larger than the critical casting thickness," the ability to create amorphous metal, or metallic glass, alloys using 3DPrinting technology, opening the door to a variety of applications in the UAV industry, such as more efficient electric motors, better wear-resistant materials, higher strength materials, and lighter weight structures. The paper is published in the journal Applied Materials Today. The paper was co-authored by Harvey West, Timothy Horn and Christopher Rock of NC State; Lena Thorsson, Mattias Unosson and Peter Skoglund of Sindre Metals; and Evelina Vogli of Liquidmetal Coatings. The work was done with support from the National Science Foundation under grant number 1549770.
The technique works by applying a laser to a layer of metal powder, melting the powder into a solid layer that is only 20 microns thick. The "build platform" then descends 20 microns, more powder is spread onto the surface, and the process repeats itself. Because the alloy is formed a little at a time, it cools quickly - retaining its amorphous qualities. However, the end result is a solid, metallic glass object - not an object made of laminated, discrete layers of the alloy.
ANSYS offers a complete simulation workflow for Additive Manufacturing (AM) that allows you to transition your R&D efforts for metal AM into a successful manufacturing operation.
Additive manufacturing (3D printing) is a technology that produces three-dimensional parts layer by layer from a variety of materials. It has been rapidly gaining popularity as a true manufacturing process in recent years.
ANSYS’ best-in-class solution for additive manufacturing enables simulation at every step in your AM process. It will help you optimize material configurations and machine and parts setup before you begin to print.
As a result, you’ll greatly reduce — and potentially eliminate — the physical process of trial-and- error testing.
ANSYS Additive simulation process
ANSYS AM simulation tools will help you:
Design for AM (DfAM) utilizing topology optimization and lattice structures
Conduct design validation
Improve build setup — with additional design features for part manufacturing, including part orientation and automatic generation of physics-based support structures
Simulate print process
Explore and gain greater understanding of materials
The ANSYS solution is especially designed for these users:
3D printing, as an additive process, offers much more than traditional machining techniques in terms of achievable complexity of a model shape.
That fact was a motivation to adapt discussed technology as a method for creating objects purposed for aerodynamic testing.
The following paper provides an overview of various 3D printing techniques. Four models of a standard NACA 0018 aerofoil were manufactured in different materials and methods: MultiJet Modelling (MJM), Selective Laser Sintering (SLS) and Fused Deposition Modeling (FDM).
Various parameters of the models have been included in the analysis: surface roughness, strength, details quality, surface imperfections and irregularities as well as thermal properties.
Army planners say they envision a portable set of interchangeable components that could be used to build a wide assortment of UAVs. Ideally, a 3-D production system would churn out the frame, while a selection of motors, sensors, cameras and other apparatus could be selected from a standing inventory: “It’s an integrated system model that allows you to match the mission to the components,” said Eric Spero, a team lead within ARL’s vehicle technology directorate. “If I know what mission I need to accomplish, I want to be able to select the most appropriate electronics and combine that with a predefined structure.”
The Army is not alone in offering up a vision for a 3D-printed UAV. Hobbyists can download instructions for build-it-yourself copters and can even buy ready-made printable drone kits on Amazon. YouTube offers video tutorials. But the military-grade project looks to go beyond these commercials offerings, by making available the widest possible range of vehicles: “Our emphasis is on inherent flexibility,”said John Gerbes, a mechanical engineer at ARL. “It’s not just about providing a 3D-printed UAV but about providing a suite of tool to meet mission-specific needs.”
The use of 3D printing, or additive technology, makes it possible to create these ad hoc solutions to meet a broad range of requirements. Rather than carry parts and pieces for every possible configuration, soldiers will be able to manufacture on the fly those components that best suit the need: “If you can scale the arms longer or shorter, that links to the motor, which links to the battery, which links to the control systems. When you can do that, that is when you are really leveraging the power of additive technology,”Spero said.
“This is one step toward giving soldiers the right tools they need when they need them,” said Larry “L.J.” Holmes, Lead, Additive Manufacturing-Hybrid Operations Team (AM-HOT) at RDECOM, the Research, Development and Engineering Command. He described UAVs as the “low-hanging fruit,” a point of interest across Army and Marine Corps user groups. But he suggested that this capability might be just a starting point as the Army seeks other areas in which 3D printing could fulfill mission-specific needs on the fly. So, why carry around UAVs... when they can be printed on the spot?
Aerospace is frequent early adopter of Additive Manufacturing as the technology promises dramatic weight reductions.
Antennas are an ever-present component in all commercial and military aircraft, as well as in satellites, UAVs and ground terminals.
However, Optisys believes they are typically too heavy, particularly with the RF antennas implemented in aerospace.
Following a partnership with U.S software company ANSYS, Optisys developed an alternative method to 3D print the components by utilizing simulation software.
With the two technologies, Optisys is able to design parts that are significantly lighter with savings of up to 95%. By doing so, Optisys states it has managed to reduce not only the number of parts, but also the weight of parts, the lead times and the production costs.
Optisys has several pending patents and is hoping to work with more aerospace companies and academics to advance the use of Additive Manufacturing in this field.
The aerospace industry is leading the way for adoption of Additive Fabrication technologies for manufacturing applications. With widespread adoption of Additive Manufacturing for jigs, fixtures, and tooling applications on the shop floor, as well as the announcements of trailblazing companies like United Launch Alliance and Airbus qualifying additive manufactured high performance thermoplastic parts for flight applications, and the printed jet UAV demonstrated in 2015, the future of the industry is starting to take shape.
The webinar will be presented by Scott Sevcik, the Senior Manager for Aerospace & Defense Business Development at Stratasys. In this role, Scott is responsible for accelerating the adoption of 3D Printing in the aerospace and defense industries globally through building partnerships for application and technology development. Prior to Stratasys, Scott led the program management team developing sensors and integrated systems for commercial transport aircraft at United Technologies Aerospace Systems. At UTAS, and Lockheed Martin before that, he led engineering teams on development projects for the SmartProbe® AirData System, the Taiwan P-3 Aircraft, and a satellite launch program. Scott also led proposal efforts for UAVs, avionics, and missile defense programs at Lockheed Martin. Scott holds Master’s degrees in Business Administration and Aerospace Engineering from San Jose State University, and a Bachelor’s degree in Aerospace Engineering with a minor in Political Science from Iowa State University.
During the webinar you will learn about:
The recent steps forward in manufacturing for the aerospace industry
The key applications in which the technology is in use
Where Additive Manufacturing for aerospace is headed
Recognizing the advances in Additive Fabrication technologies, the United States Marine Corps has set up a dedicated Additive Manufacturing program with the aim of mass-producing militaristic items with ease and at any location.
Looking deeper, it is only right to state that this program—which was heralded by the Logistics Innovation Challenge—was developed to give the US Army a considerable edge during wartime.
The program has recorded considerable successes for it led to the development of an unmanned aerial system named ‘Scout’ with reconnaissance features which was built with approximately $600.
The fourth industrial age is here to stay and the exact roles 3d Printing will play in defining how it develops can only be speculated at for now. But one thing is sure: manufacturing in every industry vertical—bio-medicine, the military, engineering, science etc.—will come to rely heavily on the on-going innovations in the field of Additive Fabrication Technologies.
This revolution would definitely have enhanced the German war effort during the battle of Stalingrad by drastically reducing the logistics associated with carting ammunitions as well as other goods from Germany and its environs to Russia. And it is also definitely going to change modern warfare as we know, it in the coming years.
Aerialtronics is a Dutch company producing commercial UAVs. Because of its 3D printingcapabilities, their UAVs can be fully customized to meet the needs of individual customers. Some UAVs are used in livestock monitoring, infrastructure inspection, and creative filming.
It was estimated that the company’s research and development costs were diminished by 50% from the use of 3D printing. 3D printing is used to create different-sized sensor equipment, GPS systems, and boxes that accommodate for cables and other electronic components.
Aerialtronics uses Stratasys 3D printing technology to build the UAVs. On a broader scale, streamlining and employing this more cost-effective process permits small companies like Aerialtronics to become a strong contender in the international UAV market. There is no doubt that 3D printed UAVs will continue to grow into even more useful applications that simplify our lives and meet our everyday needs: Imagine being able to build an UAV on the whim, and customize it to your own specifications, thus making it more affordable and accessible than ever before: This becomes a reality with today’s 3D printing capabilities. Aside from the benefit of creating custom UAVs, 3D printing offers easy upgradation opportunities: In other words, it is easier to make modifications to a 3D design, then print and test it until the desired variation is achieved. In other ways, now a user can replace broken or malfunctioning parts on an existing UAV with 3D printed ones. So far, several components can be 3D printed including the frame, landing gear, propellers, camera mount, antenna holder, and protective equipment. Another advantage of 3D printing results from building UAV parts in new lightweight materials. An UAV will perform better and fly longer when it is lighter. It also has better battery life and responsiveness to commands in-flight when it is lighter and weight is evenly distributed. The versatility of materials used for 3D printing translates into higher performance features in the UAVs.
Military branches are also focusing on 3D Printing to explore new ways to make cheaper, lighter, and more effective UAVs. A Marine Corp named Rhet McNeal created Scout, an UAV composed of 3D printed components. This UAV only costs $600 to build in comparison to a traditional one that costs hundreds of thousands of dollars. Since it is 3D printed, should the UAV receive any damage, the parts can be easily printed and replaced within hours. On the other hand, a standard-issue UAV would require weeks, sometimes months, to get a replacement through the Marine Corps’ supply line. Scout is now in the hands of Mitre Corp., a USMCUAV supplier, to undergo certification testing.
¿More examples? The University of Virginia created a 3D printed UAV for the Department of Defense that can be printed in less than a day at $2,500, including electronics development. The body of the drone only costs $800. It is known as the Razor since it appears like one long wing. Weighing in at 6 pounds with all the equipment, the Razor can fly at 40 mph for up to 45 minutes.
The features and capabilities of the Razor are not compromised by the fact that it is 3D printed: after all, it has all the same functions as a traditional UAV with GPS waypoints for navigation, mile-distance control, camera hoisting, and phone linking capabilities that extend the distance it can be controlled within. The greatest advantage of this being 3D printed is that it can be modified and reprinted on the whim.
Last but not least: Soleon is an ItalianUAV company advancing its efforts in 3D printing UAVs. Because it deals with diverse projects, including aerial photography and thermal mapping, designs ought to be flexible and quick for upgrades. Soleon uses Materialise to meet customer needs, shorten lead times, and reduce UAV weight. One of their 3D printed UAVs is called SoleonAgro, which is intended for agricultural pest control.
Chemical company Evonik, like many other chemical companies, saw the opportunity there is in 3D printing and began manufacturing materials for the technology along with its other products a while ago.
Evonik’s work with 3D printingmaterials has taken it into the realm of biocompatible implants, potentially leading to more effective treatment for people with serious bone injuries or diseases.
UAVs go well with 3D printing, and that is a good new for anyone who, like Evonik, is considering using UAVs in large-scale maintenance operations, or for many, many other purposes.
¿Is 3D printing speeding adoption of UAVs across industries and across the world? Yes: 3D printing means UAVs are easier, faster and cheaper to manufacture, and because they’re so easy and inexpensive to create, bigger risks can be taken with their design and their usage, meaning more creative applications.
Recently, Evonik began looking into UAVs as part of its plant maintenance program. The company 3D printed a multicopter and flew it over its Wesseling site. The multicopter transmitted live images of the water tower and pipe bridges to a monitor on the control unit, demonstrating its efficacy in providing support for maintenance work. “Overall, the experiment showed that drones are ideally suited as support for projects such as maintenance work,”Evonik said.
Another good example of the good marriage between 3D Printing and UAV manufacturing is the partially 3D printed Bat Bot, a marvel of engineering, designed as an alternative to traditional quadcopters, to be used in urban areas or other cramped environments. Bat Bot was designed to be used for everything from search and rescue to personal assistance. ¿Also for military? Well, the military uses of Bat Bot can’t be ignored, as UAVs have already become critical for surveillance and supply delivery, and soldiers are beginning to 3D print their own with more frequency.
