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English to Croatian: 3D printed support General field: Tech/Engineering Detailed field: Patents
Source text - English 3D printed support
14 November 2017
Europe’s lead in metal 3D printing has been strengthened by the four-year AMAZE programme, producing lighter, cheaper, organically shaped parts. ESA was among 26 academic and industrial partners developing novel processes and products for high-performance sectors.
Launched in 2013, AMAZE – short for Additive Manufacturing Aiming Towards Zero Waste and Efficient Production of High-Tech Metal Products – was the largest R&D programme for 3D printing ever run.
ESA helped to initiate the programme, which was funded by the European Commission’s Seventh Framework Programme and coordinated by the UK’s Manufacturing Technology Centre (MTC).
The Agency joined manufacturers Airbus and Thales Alenia Space in assessing prototype products for space use, while comparable end-users did the same for the automotive, aeronautics and nuclear fusion sectors.
Laser-based 3D printing
“The work of AMAZE ranges right across the process chain,” explains David Wimpenny, Chief Technologist for the National Additive Manufacturing Centre, based at the MTC.
“It includes new approaches to part design, along with the challenge of reliably finishing and inspecting the resulting parts, introducing novel materials, improving production throughput and developing common industrial standards.”
Tommaso Ghidini, heading ESA’s Structures, Mechanisms and Materials Division, comments: “The Agency’s participation in AMAZE was an opportunity to create synergies and cross-fertilising benefits with our existing Advanced Manufacturing Cross-Cutting Initiative, harnessing game changing manufacturing technologies for space.”
3D printing process
To draw maximum benefit from the process, parts need to be designed specially. With 3D printing it is only the volume of material being fused together that is paid for, with no waste to be cut away, so the lighter the weight of the part the cheaper it ends up.
David Wimpenny adds: “It’s really opened the eyes of designers: through 3D printing, complex, performance-optimised, lightweight parts actually end up costing less than traditional alternatives.
“During AMAZE we’ve been literally growing parts to bear the loads required; the result has been these organically shaped metal parts weighing less than half the of the original component, manufactured all in one – removing joints which represent potential points of weakness.
Metre-scale titanium cylinder
“This complexity means that file sizes can be huge – several orders of magnitude larger than a normal CAD file – and it can take a long while to process all that data. But another AMAZE development has been new software tools to radically reduce the time involved.”
New materials were developed to meet specific industrial needs, including the first 3D printing of InVar, an alloy of nickel and iron that is highly prized by the space sector for its ability to withstand orbital temperature extremes without expansion or contraction.
3D printing of vanadium and tungsten was also demonstrated. These high-melting point metals are suited for use within nuclear fusion reactors as well as rocket engines.
CONTINUE
Temperature-resistant InVar-printed component
Assessing a range of different 3D printing techniques, the variety of produced parts varied hugely, from millimetre-scale samples to metre-scale structural items.
“Just as important was increasing the speed and productivity of the process, from a few hundred grams to kilograms per hour, without compromising quality,” explains David Wimpenny.
“We achieved this in various ways, including increasing the number and power of the lasers used for material melting.”
Pylon brackets
“We’ve also worked to ensure the powder feedstock is optimised for the process. The powder particles have to have the correct size and shape to provide the right flow properties to give consistently high-quality, defect-free layers.”
Another challenge was the post processing, finish and inspection of the parts, including standardised non-destructive test procedures. Medical-style three-dimensional CT scanning is one solution that was explored, with AMAZE findings going towards an ongoing effort to develop a common ISO standard for the field.
“The industrial partners in the project are now commercialising the results of the project and the AMAZE experience has helped to forge a research community which will continue to increase the knowledge and improve the capability of additive manufacturing processes going forwards”, says David Wimpenny.
Checking print quality
For instance, Norsk Titanium – supported by developments made during AMAZE – has become the first company to manufacture structural aircraft components using metal 3D printing.
Tommaso explains that the ESA–RAL Advanced Manufacturing Lab at Harwell in the UK, has played an important role in assessing the performance of AMAZE’s aeronautical and space outputs: “It has helped to define verification strategies used for critical applications, putting them on a fast track for adoption by projects.”
David Wimpenny concludes that AMAZE has helped maintain Europe’s pre-eminence in the field of metal 3D printing, “But we shouldn’t be complacent. Global competition is fierce and it’s critically important Europe maintains its lead.”
Translation - Croatian 3D printana potpora
Vodeća europska tvrtka za 3D printanje osnažena je četverogodišnjim AMAZE programom i sada proizvodi laganije, jeftinije, organski oblikovane dijelove. ESA je bila jedna od 26 akademskih i industrijskih partnera koji su radili na razvoju novih procesa i proizvoda za sektore visoke izvedbe.
Pokrenut 2013, AMAZE- skraćeno od Proizvodnja aditiva čiji je cilj izbaciti otpad i učinkovita proizvodnja visokotehnoloških metalnih proizvoda- bio je najveći R&D program za 3D printanje koji je ikada pokrenut.
ESA je pomogla potaknuti program, koji je financiran od strane Sedmog okvirnog programa Europske komisije, a koordinirao ga je Centar za proizvodnju tehnologije iz Ujedinjenog kraljevstva (MTC).
Agencija se pridružila proizvođačima Airbus i Thales
Alenia Space u procjeni prototipa proizvoda za uporabu u svemirskom programu, dok su usporedni krajnji korisnici učinili isto sa automobilskim, aeronautičkim i sektorom nuklearne fuzije.
Lasersko 3D printanje
"Rad AMAZE programa doseže upravo lanac proizvodnje", objasnio je David Wimpenny, glavni tehnolog u Centru za nacionalnu proizvodnju aditiva, koja se bazira na MTC.
"Ovo uključuje nove pristupe dizajniranju dijelova, a s time dolaze i izazovi pouzdanog završetka i provjere završnog proizvoda, predstavljajući nove materijale i poboljšavajući proizvodnu propusnost uz razvoj općih industrijskih standarda."
Tommaso Ghidini, voditelj ESA-inog odjela Strukture, mehanizmi i materijali, komentira: "Sudjelovanje naše agencije u AMAZE programu prilika je za stvaranje korisne i plodne sinergije s našim postojećom Naprednom proizvodnom preklapajućom inicijativom koja upreže revolucionarne proizvodne tehnologije za svemirski program."
Proces 3D printanja
Da bismo izvukli maksimalnu korist iz ovog procesa, dijelove trebamo posebno dizajnirati. Kod 3D printanja isplati se jedino ako se neka količina materijala spoji zajedno, bez ikakvog otpada, tako da, što je manja težina nekog dijela, niža će mu biti i cijena.
David Wimpenny je dodao: "Ono što je otvorilo oči dizajnerima je to da su kroz proces 3D printanja složeni, lagani i dijelovi poboljšane izvedbe u konačnici zapravo jeftiniji u odnosu na neke tradicionalne alternative.
Kroz AMAZE program mi doslovno "uzgajamo" dijelove da bismo zadovoljili veliku potražnju; rezultat toga su ovi organski oblikovani metalni dijelovi koji teže upola manje od originalnih komponenti i proizvedeni su kao jedna cjelina bez spojnih točki, koje predstavljaju slabije točke."
Jednometarski cilindar od titana
"Ova složenost znači da veličine datoteka mogu biti ogromne- nekoliko redova veličina veće od normalne CAD datoteke- i može poprilično dugo trajati da bi se svi ti podaci obradili. Stoga je još jedan novi napredak AMAZE programa razvoj novih alata softwera u svrhu radikalnog smanjenja tog vremena."
Da bi se ispunili zahtjevi tržišta, razvijeni su novi materijali, uključujući i prvo 3D printanje InVara, legure nikla i željeza koja je jako cijenjena u svemirskom sektoru, zbog svoje mogućnosti podnošenja temperaturnih ekstrema u orbiti, a da se ne proširi, niti smanji.
3D printanje vanadija i volframa također je prikazano. Ovi metali visoke točke tališta prilagođeni su za uporabu u reaktorima nuklearne fuzije, kao i kod raketnih pogona.
InVarove printane komponente koje su otporne na temperaturu određuju raspon različitih tehnika 3D printanja, raznolikost proizvedenih dijelova je velika, od milimetrskih uzoraka pa sve do jednometarskih strukturnih proizvoda.
"Isto tako, bilo uje važno povećati brzinu i produktivnost tog procesa, od nekoliko stotina grama do nekoliko kilograma na sat, bez žrtvovanja kvalitete," objasnio je David Wimpenny.
"Ovo smo postigli na različite načine, povećavajući broj i snagu lasera koji se koriste za topljenje tvari."
Pilonske zagrade
"Također smo se trudili da osiguramo optimalne sirovine pudera za taj proces. Čestice pudera trebaju biti odgovarajuće veličine i oblika da bi osigurale odgovarajuća svojstva protoka za dobijanje dosljednih visokokvalitetnih slojeva, koji će biti bez mane."
Dodatni izazov bio je postproizvodni proces, završavanje i pregledavanje dijelova, uz pomoć standardiziranih, nedestruktivnih testnih postupaka.
Medicinsko, trodimenzionalno CT snimanje je jedno od rješenja koje je istraženo, uz saznanja AMAZE programa, koja su u neprekidnom nastojanju razvoja općeg ISO standarda za ovo polje.
"Industrijski partneri u ovom projektu sada komercijaliziraju rezultate projekta i AMAZE iskustvo
pomoglo im je krivotvoriti istraživačku zajednicu koja će nastaviti povećavati znanje i poboljšavati mogućnost unapređenja dodatnih proizvodnih procesa," kaže David Wimpenny.
Kontrola kvalitete printanja
Na primjer, Nordijski titan- uz potporu razvoja kroz AMAZE program- postao je prva tvrtka za proizvodnju strukturnih dijelova letjelica uz uporabu 3D printanih metala.
Tommaso objašnjava da je ESA-RAL Laboratorij za naprednu proizvodnju u Harwellu, u Ujedinjenom kraljevstvu, igrao važnu ulogu u procjeni izvedbe AMAZE-ovih aeronautičkih i svemirskih snaga: "To je pomoglo definirati strategije provjere koje se koriste za kritične aplikacije, time ubrzavajući njihovo prihvaćanje za projekte."
David Wimpenny zaključuje da je AMAZE pomogao zadržati europsku nadmoć na području 3D printanja metala. "Ali, ne bismo trebali biti spokojni. Globalna konkurencija je žestoka i kritički je važno da Europa zadrži svoje vodstvo na tom području."
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