Renishaw, HiETA & nTopology Support Cobra Aero in the Design, Development and Production of a Novel UAV Engine

Cobra Aero, a successful producer of two-stroke engines for UAV applications approached Renishaw to understand how they could incorporate additive manufacturing into their existing manufacturing portfolio.

Cobra had a vision for the use of metal Additive Manufacturing (AM) in their business, and enlisted additional help from HiETA and nTopology to help drive the development of an innovative engine design.

Leveraging the design opportunities of AM and the expertise of the partners involved, Cobra have devised a pioneering and extremely performant new engine design.

Moreover, Cobra have explored the applications space including production of tooling, complex componentry and highly customized components in their sister motorcycle business, Cobra Moto.

Primary Topics: • Design for Manufacture • Aerospace Design • Complex Structures for Heat Exchange • Product Innovation and Testing Speaker: Kevin Brigden Additive Applications Engineer, Renishaw

Kevin has a master's degree in engineering with honors in motorsports engineering from the University of Central Lancashire, England. A member of a team of technical specialists, he brings a skill-set centered in computer-aided engineering (CAE) including computer-aided design (CAD), finite element analysis (FEA) and computational fluid dynamics (CFD). During Kevin's time with Renishaw, he has led and consulted on numerous design projects in collaboration with partners and customers from aerospace, automotive, space and defense and medical engineering. Kevin is at the forefront of the design for additive manufacture (DfAM) movement, with many of his characteristic and innovative designs widely recognized and imitated.

More info:

https://register.gotowebinar.com/register/2915462139651536141?source=web

Models for wind tunnel tests based on additive manufacturing technology

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.

Read more:

https://www.sciencedirect.com/science/article/pii/S0376042118301866

Emerging Threats: Cyber-Physical Attacks on Additive Manufactured UAV Parts

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 AM generated 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.

(Read more...)

Research supporting principles for DFAM

Additive Manufacturing (AM) technologies enable the fabrication of parts and devices that are geometrically complex, have graded material compositions, and can be customised.

To take advantage of these capabilities, it is important to guide engineering designers through the various issues that are unique to AM. We explore the range of principles that are relevant to Design For Additive Manufacturing (DFAM) in this paper.

These include ideas about generating designs that cannot be fabricated using conventional methods to understanding the realities of existing machines and materials to micro-scale issues related to material microstructures and resulting process variations.

Comments about standardisation efforts in the ASTM and ISO organisations are also included.

(Read More)

Design for Additive Manufacturing

Design For Manufacturing (DFM) has typically meant that designers should tailor their designs to eliminate manufacturing difficulties and minimize manufacturing, assembly, and logistics costs.

However, the capabilities of Additive Manufacturing (AM) technologies provide an opportunity to rethink DFM to take advantage of the unique capabilities of these technologies:

1) Shape complexity: It is possible to build virtually any shape.

2) Hierarchical complexity: Hierarchical multiscale structures can be designed and fabricated from the microstructure through geometric mesostructure (sizes in the millimeter range) to the part-scale macrostructure

3) Material complexity: Material can be processed one point, or one layer, at a time.

4) Functional complexity: Fully functional assemblies and mechanisms can be fabricated directly using AM processes.

These unique capabilities enable new opportunities for customization, very significant improvements in product performance, multifunctionality, and lower overall manufacturing costs.

In the case of UAVs, AM technology enables low-volume manufacturing, easy integration of design changes and, at least as importantly, piece part reductions to greatly simplify product assembly.

(Read more)

Additive Manufacturing in UAVs: Challenges and potential

UAVs are gaining popularity due to their application in military, private and public sector, especially being attractive for fields where human operator is not required.

Light-weight UAVs are more desirable as they have better performance in terms of shorter take-off range and longer flight endurance. However, light weight structures with complex inner features are hard to fabricate using conventional manufacturing methods.

The ability to print complex inner structures directly without the need of a mould gives Additive Manufacturing (AM) an edge over conventional manufacturing. Recent development in composite and multi-material printing opens up new possibilities of printing lightweight structures and novel platforms like flapping wings with ease.

This paper explores the impact of Additive Manufacturing on aerodynamics, structures and materials used for UAVs. The review will discuss state-of-the-art AM technologies for UAVs through innovations in materials and structures and their advantages and limitations. The role of Additive Manufacturing to improve the performance of UAVs through smart material actuators and multi-functional structures will also be discussed.

(Read more)

The Additive Manufacturing Revolution

Additive Manufacturing (AM) doesn’t offer anything like that economy of scale. However, it avoids the downside of standard manufacturing: a lack of flexibility. Because each unit is built independently, it can easily be modified to suit unique needs or, more broadly, to accommodate improvements or changing fashion. And setting up the production system in the first place is much simpler, because it involves far fewer stages. That’s why Additive Fabrication has been so valuable for producing one-offs such as prototypes and rare replacement parts.

Additive Fabrication Technology is at a tipping point, about to go mainstream in a big way: Among the numerous companies using Additive Technology to ramp up production are GE (jet engines, medical devices, and home appliance parts), Lockheed Martin and Boeing (aerospace and defense), Aurora Flight Sciences (UAVs), Invisalign (dental devices), Google (consumer electronics), and the Dutch company LUXeXcel (lenses for light-emitting diodes, or LEDs). Regarding UAVs, in Iraq and Afghanistan the U.S. military has been using UAVs from the Aurora Flight Sciences company, which prints the entire body of these UAVs —some with wingspans of 132 feet—in one build.

(Read more)

Integration of Topological and Functional Optimization in Design for Additive Manufacturing

Additive Manufacturing (AM) technologies has brought unprecedented freedom to the fabrication of functional parts with high complex, multi-material and gradient density structure.

However, currently only traditional design methods are available for AM design process, which do not take full advantage of AM capabilities. Therefore, a new design method with the consideration of all aspects of AM advantages is urgently in need.

A detailed literature review on traditional design methods is presented with focused attention on the potential of using these methods to design functional parts for Additive Manufacturing processes. Based on thorough understanding and comparison of current structure design methods, a new design approach that integrates topological and functional optimizations for AM products is presented.

With this method, an essential link is established between topological optimization result and various functional parameters of complex structure. Parts can be designed in multi levels for multi functions simultaneously. This design method provides an important foundation for future research on designing AM products with improved multiple functions and optimized topology.

Read more:

http://proceedings.asmedigitalcollection.asme.org/proceeding.aspx?articleid=1919996

Ansys: Additive Manufacturing Simulation

Additive Manufacturing Simulation

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:

• Aerospace OEMs and suppliers
• Metal AM print services bureaus
• Biotech companies with AM efforts
• Automotive OEMs and suppliers
• AM materials R&D companies
• Metal AM machine manufacturers

Examples

Part Accuracy Prediction

Distortion compensation Filter Example

Distortion Compensation for Additive Manufacturing

Print Process Simulation

Additive Manufacturing: Making Imagination the Major Limitation

Additive Manufacturing (AM) refers to an advanced technology used for the fabrication of three-dimensional near-net-shaped functional components directly from computer models, using unit materials.

The fundamentals and working principle of AM offer several advantages, including near-net-shape capabilities, superior design and geometrical flexibility, innovative multi-material fabrication, reduced tooling and fixturing, shorter cycle time for design and manufacturing, instant local production at a global scale, and material, energy, and cost efficiency.

Well suiting the requests of modern manufacturing climate, AM is viewed as the new industrial revolution, making its way into a continuously increasing number of industries, such as aerospace, defense, automotive, medical, architecture, art, jewelry, and food.

This overview was created to relate the historical evolution of the AM technology to its state-of-the-art developments and emerging applications. Generic thoughts on the microstructural characteristics, properties, and performance of AM-fabricated materials will also be discussed, primarily related to metallic materials.

This write-up will introduce the general reader to specifics of the AM field vis-à-vis advantages and common techniques, materials and properties, current applications, and future opportunities.

Read more: https://link.springer.com/article/10.1007/s11837-014-0886-2

Report On AM For UAV Manufacturing: $2.3 Billion In Value By 2027

In this report, it is projected that the yearly value of AM manufactured parts in the UAV industry to reach $1.9 billion, driving over $400 million in yearly sales of AM equipment, software, materials and services. Further details of this report including a detailed description, table of contents and downloadable excerpt can be found at: https://smarttechmarke.wpengine.com/product/additive-manufacturing-for-the-droneuav-industry-an-opportunity-analysis-and-ten-year-forecast/. 

Integration of Topological and Functional Optimization in Design for Additive Manufacturing

Additive Manufacturing (AM) technologies has brought unprecedented freedom to the fabrication of functional parts with high complex, multi-material and gradient density structure.

However, currently only traditional design methods are available for AM design process, which do not take full advantage of AM capabilities. Therefore, a new design method with the consideration of all aspects of AM advantages is urgently in need.

A detailed literature review on traditional design methods is presented with focused attention on the potential of using these methods to design functional parts for additive manufacturing processes. Based on thorough understanding and comparison of current structure design methods, a new design approach that integrates topological and functional optimizations for AM products is presented.

With this method, an essential link is established between topological optimization result and various functional parameters of complex structure. Parts can be designed in multi levels for multi functions simultaneously. This design method provides an important foundation for future research on designing AM products with improved multiple functions and optimized topology.

Read more: http://proceedings.asmedigitalcollection.asme.org/proceeding.aspx?articleid=1919996

Additive manufacturing in UAVs: Challenges and potential

UAVs are gaining popularity due to their application in military, private and public sector, especially being attractive for fields where human operator is not required.

Light-weight UAVs are more desirable as they have better performance in terms of shorter take-off range and longer flight endurance. However, light weight structures with complex inner features are hard to fabricate using conventional manufacturing methods.

The ability to print complex inner structures directly without the need of a mould gives Additive Manufacturing (AM) an edge over conventional manufacturing. Recent development in composite and multi-material printing opens up new possibilities of printing lightweight structures and novel platforms like flapping wings with ease.

This paper explores the impact of Additive Fabrication on aerodynamics, structures and materials used for UAVs. The review will discuss state-of-the-art

AM technologies for UAVs through innovations in materials and structures and their advantages and limitations. The role of Additive Fabrication Technology to improve the performance of UAVs through smart material actuators and multi-functional structures will also be discussed.

More info:

https://www.researchgate.net/profile/Shweta_Agarwala/publication/311978361_Additive_manufacturing_in_unmanned_aerial_vehicles_UAVs_Challenges_and_potential/links/59dad4e6aca272e6096bf240/Additive-manufacturing-in-unmanned-aerial-vehicles-UAVs-Challenges-and-potential.pdf

GA-ASI selects GKN to create fuel bladders for MQ-9B

GKN Aerospace has signed a development agreement with General Atomics Aeronautical Systems, Inc. (GA-ASI) covering the design, development and manufacture of fuel bladders for the MQ-9B Remotely Piloted Aircraft (RPA) system.

GKN Aerospace develops, builds and supplies an extensive range of advanced aerospace systems and components made by Additive Manufacturing (AM) and other innovative manufacturing technologies focused to reduce weight on the aircrafts.

GKN Aerospace will work in conjunction with GA-ASI to design and manufacture the fuel bladders at the GKN Aerospace facility in Tallassee, Alabama. Stefan Svenson, vice president of GKN Aerospace Special Products Group said: “We look forward to working with GA-ASI to provide a vital fuel system solution for this long-endurance Predator B platform variant. We have been supplying fuel systems for many decades and for many airframe platforms and MQ-9B fully exploits all our recent advances in both manufacturing and materials technologies.”

The agreement covers the fuel bladder system for the first production aircraft slated for 2018, with a potential full contract value of USD 15M when the aircraft enters into service with NATO’s UAV AIRWORTHINESS REQUIREMENTS (defined in STANAG 4671). MQ-9B is a "Type-Certifiable" version of GA-ASI’s Predator® B product line. The target is to create fuel bladders in complex shapes that fully exploit all available space on the MQ-9B airframe, maximizing the fuel load capacity and platform endurance.

General Atomics looks for an Additive Manufacturing Machine Technician

Duties & Responsibilities

Follow established procedures, assembly documentation, work instructions, methods and sequence of operation related to the creation of production parts and tooling using Additive Manufacturing (AM) (3D Printing), FDM and SLS techniques.

Essential Functions

Setup, operate and perform daily maintenance on AM machines.

Desirable Qualifications

Background in FDM (Fused Deposition Modeling) and/or Selective Laser Sintering (SLS) AM technologies.

More info:

https://www.linkedin.com/jobs/view/additive-manufacturing-machine-technician-at-general-atomics-503569977/

Additive Manufacturing as a Challenge For New FAA Certification Approach

The first step towards the regulatory approval for use of Additive Manufacturing (AM) also known as 3D Manufacturing in aviation occurred when Dr. Michael Gorelik, FAA chief scientific and technical adviser for fatigue and damage tolerance, announced that a roadmap towards that eventuality has been created.

The FAA sent a draft version of its Additive Manufacturing Strategic Roadmap to the agency management team for evaluation and the document suggests production, certification, maintenance policies the agency aims to establish over the next seven to eight years.

(Read More...)

Pushing the Cutting Edge of Robots and UAVs

Additive manufacturing (AM), advances in sensing, computer vision, artificial intelligence and other technologies have come together to create a world of possibilities. “They’ve opened up a lot of use cases that we couldn’t even think about five years ago,” said John Lizzi, robotics breakout leader for GE Global Research. “How do you get these things to work together in collaborative ways?”

(Read More...)

Industry 4.0 and the Evolution of Small, Smart, and Cheap Weapons

Dramatic improvements in Robotics, AI (Artificial Intelligence), AM (Additive Manufacturing, also known as 3D Printing), and Nanoenergetics are dramatically changing the character of conflict in all domains.

The convergence of these new and improving technologies is creating a massive increase in capabilities available to smaller and smaller political entities — extending even to the individual.

This increase provides smaller powers with capabilities that used to be the preserve of major powers. Moreover, these small, smart, and cheap weapons based on land, sea, or air may be able to dominate combat.

This new diffusion of power has major implications for the conduct of warfare and national strategy. Because even massive investment in mature technology leads to only incremental improvement in capabilities, the proliferation of many small and smart weapons may simply overwhelm a few exceptionally capable and complex systems.

The advances may force the United States to rethink its procurement plans, force structure, and force posture. The diffusion of power will also greatly complicate U.S. responses to various crises, reduce its ability to influence events with military force, and should require policymakers and military planners to thoughtfully consider future policies and strategy.

(Read more...)

Additive manufacturing in UAVs: Challenges and potential

UAVs (Unmanned Aerial Vehicles) are gaining popularity due to their application in military, private and public sector, especially being attractive for fields where human operator is not required.

Light-weight UAVs are more desirable as they have better performance in terms of shorter take-off range and longer flight endurance. However, light weight structures with complex inner features are hard to fabricate using conventional manufacturing methods.

The ability to print complex inner structures directly without the need of a mould gives Additive Manufacturing (AM) an edge over conventional manufacturing. Recent development in composite and multi-material printing opens up new possibilities of printing lightweight structures and novel platforms like flapping wings with ease.

This paper explores the impact of additive manufacturing on aerodynamics, structures and materials used for UAVs. The review will discuss state-ofthe-art

AM technologies for UAVs through innovations in materials and structures and their advantages and limitations. The role of additive manufacturing to improve the performance of UAVs through smart material actuators and multi-functional structures will also be discussed.

(Read More)

Additive Manufacturing for the Drone/UAV Industry 2017-2027

In this report, the firm Research and Markets projects that the yearly value of Additive Manufacturing (AM) in the UAV (Unmanned Aerial Vehicle) industry to reach $1.9 billion, driving over $400 million in yearly sales of AM equipment, software, materials and services.

The Drone AM report also provides information on which companies and institutions in the space infrastructure industry are using additive manufacturing today, with relevant case studies. Key firms in the drone AM segment include: Boeing, CRP Group, DJI, EHANG, EOS, General Atomics, HP, Hubsan, Lockheed Martin, Northrop Grumman, Oxford Performance Materials (OPM), Parrot, Ricoh,  Stratasys, 3D Systems and 3DR.

The report includes an in-depth analysis of the materials used for drone AM prototyping and production, which takes into consideration both high performance polymers and metals as well as composites, ceramics and technologies for direct 3D printing of electronics.

For more information about this report visit https://www.researchandmarkets.com/research/7mvrn7/additive