Video: 3D Printing Exotic High Temp Alloys - The Future Is Now! (GE Aviation)
Thursday, May 23, 2013 at 08:25AM
I don't care if you're a tube-and-rag tailgragger lover like me or a jet-jockey driving an F-22 around the sky, if this video doesn't make your mind race with the possibilities (now, and especially in the future) then I don't know what will. This video from GE Aviation reveals technology where they literally 3D print high-temp exotic-alloy turbine engine parts!
It's called DMLM (Direct Metal Laser Melting) and it's an 'additive manufacturing' process rather than subtractive... instead of cutting metal away you simply add the metal where you want it. It's not only an insanely awesome way to envision metal part building but it also allows for parts to be made that otherwise couldn't be. Drilling and machining can't always get where you need to be to get a part to function a certain way. Additive manufacturing has essentially no limits as to the complexity of the design, which not only allows for everything to be possible but it also means that multiple parts can now be produced as a single unit. The whole process can save weight while also increasing operating efficiencies of the components being produced.
Video screenshot: High-temp metal fuel nozzle for a GE turbine engine... 3D printed!
I think most of us are getting pretty used to the idea of being able to 3D print parts in plastic these days, and research indicates that basic metal 3D printing processes have been around for many years now (especially in the repair world), but the amazing idea here is that we can now create critical high-temp parts from exotic alloys and seriously consider using them in areas where failure is not an option. Truly amazing and exciting technologies!
The future is now.
Reader Comments (8)
Looks great, but I don't think they can get a single crystal structure and make the turbine blades with this technology...
What this kind of tech gets me excited about is that a lot of rare older aircraft parts may become available again. Where it would previously have been insanely expensive to produce a few new spare parts for a Merlin engine, for example, if you can just print them as needed, suddenly the cost becomes a lot more reasonable.
Maybe someday soon we'll see a few "new" warbirds with all of their proprietary parts printed as needed, running "new" Merlin engines built from a combination of printed and CNC machined parts.
Less jobs in the industry, A printer & a trained monkey, A few cubical hamsters too.
And little to no extra/wasted material. This is exciting stuff.
@don: The end goal of industry is not to create or retain jobs, it is to produce. This technology will reduce cost and complexity in machine design. General aviation desperately needs modern solutions like this.
The object of industry is to make money. If they can hire Monkeys & cubical hamsters it reduces cost, Arron it will not reduce the cost for the consumer but add to profits.
Cessnas for $170,000 ? Yep. A new part for $13.000 Yep.
Salvage parts ! Yeeeee Hawwwww!
The idea that an individual or small business can have access to this kind of technology is a game changer. Yes, it is disruptive but so was the automobile to the horse and buggy industry. Technological advancement, by definition, is disruptive. Will it put machinists out of work? Some, perhaps. But there will always be a need for them and new technology spawns new industries.
It will reduce costs for the consumer--particularly the home builder. Imagine being able to print a door handle, or knob, etc, etc. What's the alternative for custom parts? What about parts that aren't even available any more? This technology will allow 3D designs to be distributed throughout the community and parts to be printed without 6 and 7 figure investments in CNC mills. Because it won't require highly skilled operators, the demand for 3D printers will be high. Economies of scale will eventually drive the costs of 3D printers WAY down. That's a good thing.
As far as commercial applications go, reducing costs ALWAYS results in lower prices for the customer (provided there's genuine competition).
Aaron- right on! #future
I wonder how the metal reacts to the heating process in the 3D printer, it might cause impurities in the metal.
I just received a 3D printed part and I kept it in water over night and the stainless steel piece showed a lot of rust the next morning.