Addithive

Tag: additive manufacturing

  • Medical Additive Manufacturing: Devices, Patient-Specific Workflows and Regulatory Controls

    Medical Additive Manufacturing: Devices, Patient-Specific Workflows and Regulatory Controls

    Medical additive manufacturing includes several very different activities: anatomical models, surgical guides, standard implants, patient-matched devices, prosthetics, instruments and early-stage bioprinting research. Each application has a different risk profile, evidence burden and manufacturing route.

    A material described as biocompatible is not automatically a safe medical device. The intended use, finished geometry, manufacturing process, cleaning, sterilization and clinical performance must be evaluated together.

    Medical AM application map

    ApplicationTypical valueMain controls
    Anatomical modelsVisualization, education and surgical planningImage segmentation, dimensional accuracy and intended-use labeling
    Surgical guidesTransfer a digital plan to the patient during a procedureFit, guide geometry, sterilization and procedural validation
    Patient-matched implantsGeometry adapted to a patient’s anatomyImaging data, design boundaries, mechanical performance and traceability
    Standard porous implantsRepeatable lattice or porous structures for fixationProcess validation, fatigue, residue removal and biological evaluation
    External prostheses and orthosesCustomization, comfort and rapid iterationFit, load capacity, skin contact and durability
    Instruments and fixturesComplex geometry and low-volume productionCleaning, sterilization, strength and lifecycle testing
    Drug and biologic researchNovel dosage forms, scaffolds and laboratory modelsApplication-specific drug or biologic regulation
    Bioprinting researchCellular constructs and research modelsCell viability, biology, vascularization and translational evidence

    Standard designs vs patient-matched devices

    Not every medical AM part is patient specific. Many commercially manufactured spine cages, orthopedic implants and instruments are produced repeatedly from standard designs. Patient-matched devices use imaging or anatomical data to create a defined variation within an approved design envelope.

    Personalization increases the importance of software validation, segmentation review, design rules and data traceability. A unique geometry does not remove the requirement for controlled manufacturing or device testing.

    The patient-specific digital workflow

    1. Acquire patient data: CT, MRI, optical scan or another validated source is collected at appropriate resolution.
    2. Segment the anatomy: Relevant structures are separated from the medical image and reviewed for artifacts or missing information.
    3. Create the device or model: The design is generated within approved rules, offsets and anatomical interfaces.
    4. Clinical and engineering review: Qualified personnel confirm intended use, fit, orientation and critical features.
    5. Prepare the build: Orientation, supports, nesting and process parameters are released.
    6. Manufacture and post-process: Printing, cleaning, heat treatment, machining, finishing or curing are performed under controlled instructions.
    7. Inspect and test: Identity, geometry, material and functional requirements are verified.
    8. Clean, package and sterilize: The validated route is completed where required.
    9. Release and retain records: The part is linked to patient, design, software, machine, material and processing history.

    The FDA describes a similar chain covering device design, software workflow, material controls, printing, post-processing, validation and testing.

    Process and material selection

    ProcessCommon medical roleImportant limitations
    Metal laser powder bed fusionTitanium, cobalt-chromium and selected implant or instrument applicationsResidue, surface condition, fatigue, heat treatment and NDT
    Electron-beam powder bed fusionSelected titanium implants and porous structuresPowder-cake removal, feature resolution and platform-specific material routes
    Polymer powder bed fusionModels, instruments, orthoses and selected devicesPowder reuse, moisture, porosity and sterilization compatibility
    Vat photopolymerizationModels, guides, dental devices and selected patient-contact productsResin identification, washing, post-cure, extractables and aging
    Material extrusionModels, prosthetics, fixtures and research devicesAnisotropy, porosity, dimensional accuracy and cleaning
    Material jettingMulti-color or multi-material anatomical modelsMaterial aging, support removal and limited structural performance
    Bioprinting platformsResearch constructs, tissues and disease modelsBiological complexity and early translational maturity

    Design and manufacturing controls

    The FDA’s final guidance on additively manufactured medical devices organizes technical considerations around design/manufacturing and device testing. A practical control plan should address:

    • Device orientation and build location
    • Minimum feature capability and dimensional compensation
    • Support removal and inaccessible surfaces
    • Feedstock or resin specifications and lot control
    • Machine, software and parameter validation
    • Heat treatment, HIP, washing, post-curing and machining
    • Process monitoring and change control
    • Worst-case geometry and build configuration
    • Part identification and patient-data linkage
    • Supplier and production-site controls

    Cleaning and residue removal

    Complex AM geometry can trap powder, uncured resin, support material, solvent or process debris. Cleaning validation should consider the actual device geometry rather than an easily accessible test coupon.

    • Define internal passages, pores and lattices that can retain residue.
    • Validate the cleaning process at worst-case locations.
    • Measure extractable or recoverable residue using appropriate methods.
    • Control cross-contamination between materials and patient-specific jobs.
    • Confirm that cleaning does not damage surface, dimensions or material properties.
    • Retain evidence linking cleaning parameters to the released device.

    ASTM F3335 provides guidance for assessing residue removal from powder-bed-fusion medical devices and is recognized by the FDA.

    Biocompatibility and material claims

    Biocompatibility is assessed for the finished device in its intended contact condition. Relevant variables can include:

    • Base chemistry and additives
    • Powder reuse or resin aging
    • Build orientation and surface area
    • Heat treatment, post-cure and cleaning
    • Residual particles, monomers, solvent or support material
    • Coatings, polishing and machining
    • Contact type, location and duration

    A resin or alloy cleared or used for one application should not be assumed acceptable for another indication or contact type.

    Sterilization and dimensional stability

    Sterilization can alter polymer dimensions, mechanical properties, surface condition and residual chemistry. Metal devices can also be affected by packaging, cleaning or repeated processing. The selected method—such as steam, radiation or gas—must be compatible with the finished device and its intended lifecycle.

    • Measure dimensions and function after the complete sterilization route.
    • Evaluate repeated cycles for reusable devices.
    • Confirm that packaging permits effective sterilization and protects the device.
    • Control time between manufacturing, cleaning, sterilization and use.
    • Use the same post-processing condition for performance and biological testing.

    Mechanical and functional testing

    Test methods should represent the actual device, loading and manufacturing route. Depending on the application, evidence can include:

    • Static strength and fatigue
    • Wear, corrosion and fretting
    • Porous-structure characterization
    • Dimensional and fit verification
    • Pressure, flow or leak performance
    • Sterilization and shelf-life effects
    • Usability and procedural performance
    • Biological evaluation and clinical evidence as required

    ASTM F3604-23 provides a framework for validating laser-powder-bed-fusion production systems used for medical devices, including machine qualification, software, raw materials and IQ/OQ/PQ concepts.

    Point-of-care manufacturing

    Hospitals and clinical centers may use 3D printing for models, guides or other devices. Point-of-care location does not remove manufacturing responsibility. Governance should define:

    • Who is the legal manufacturer?
    • Who approves segmentation and design?
    • Which software, printer and material combinations are validated?
    • How are maintenance, environmental conditions and operators controlled?
    • How are patient data, cybersecurity and privacy protected?
    • How are nonconformances and adverse events handled?
    • Which records are retained and for how long?

    Bioprinting: promising research, different maturity

    Bioprinting uses cells, biomaterials or biologically active materials to create research constructs. It should not be grouped with commercially mature metal implants or surgical guides. Major challenges include cell viability, vascularization, tissue maturation, reproducibility, immune response and long-term function. Claims about printing complete transplantable organs remain research-stage rather than routine clinical manufacturing.

    Medical AM readiness checklist

    1. The intended use and regulatory classification are defined.
    2. Design inputs and patient-matching boundaries are controlled.
    3. The exact material, machine and post-process route is validated.
    4. Worst-case geometry can be cleaned and inspected.
    5. Finished-device biocompatibility and sterilization are addressed.
    6. Mechanical and functional testing represents final condition.
    7. Software, imaging and segmentation are verified.
    8. Traceability links patient, design, build, material and processing records.
    9. Changes to site, machine, software or material trigger defined review.
    10. Clinical claims match the available evidence.

    Conclusion

    Medical additive manufacturing is already mature in selected areas such as hearing aids, dental workflows and porous metal implants, while other areas remain developmental. Success depends on matching the process to a defined medical need and validating the complete finished-device route—from patient data and design through cleaning, sterilization, testing and traceability.

    Related Addithive resources: Dental Additive Manufacturing · Straumann Dental AM Profile · NDT for AM

    References and further reading

  • Is 3D Printing the Key to Colonizing Mars, or Just a Science Fiction Fantasy?

    Is 3D Printing the Key to Colonizing Mars, or Just a Science Fiction Fantasy?

    Since the dawn of space exploration, humanity has been fascinated by the possibility of colonizing other planets. Mars, in particular, has captured the imagination of scientists, engineers, and the general public alike. However, the challenges of establishing a human settlement on the Red Planet are enormous, and many experts believe that it will require a combination of innovative technologies to make it possible. One such technology that has been suggested as a potential key to Mars colonization is 3D printing.

    3D printing, also known as additive manufacturing, is a process in which digital 3D models are transformed into physical objects by building up layers of material. This technology has already been used to create a wide range of products, from medical implants and prosthetics to airplane parts and even entire buildings. In the context of space exploration, 3D printing has the potential to revolutionize the way that we build structures and create tools and equipment.

    One of the key advantages of 3D printing in the context of Mars colonization is the ability to manufacture objects on-site, using locally available materials. Mars is rich in resources such as iron, aluminum, and silicon, which can be used as raw materials for 3D printing. This means that instead of having to transport everything from Earth, we could potentially build many of the structures and tools needed for a Martian settlement using materials that are already on the planet. This would greatly reduce the cost and complexity of the mission, and make it more feasible in the long run.

    Another advantage of 3D printing is the ability to create complex geometries and designs that would be difficult or impossible to produce using traditional manufacturing techniques. This is particularly important in the context of space exploration, where weight and volume are at a premium. By using 3D printing to create lightweight, optimized structures, we can reduce the amount of material that needs to be transported to Mars, and make the mission more efficient.

    One of the most exciting applications of 3D printing in the context of Mars colonization is the potential to print habitats and other structures using locally sourced materials. NASA, in partnership with the University of Southern California, has already developed a prototype Mars habitat that was printed using a mixture of basaltic rock and a binding agent. This structure was designed to be strong, lightweight, and radiation-resistant, and could potentially be scaled up to create larger habitats and structures in the future.

    In addition to habitats, 3D printing could also be used to create other types of infrastructure on Mars, such as roads, landing pads, and storage facilities. These structures could be built using a variety of materials, including regolith (the loose, rocky material that covers the surface of Mars), which could be processed and used as a building material.

    However, while the potential benefits of 3D printing for Mars colonization are clear, there are also significant challenges and limitations to consider. One of the biggest challenges is the harsh environment of Mars, which presents a number of technical hurdles that must be overcome in order to make 3D printing feasible. For example, the low atmospheric pressure on Mars could make it difficult to create a stable printing environment, and the extreme temperatures could cause problems with the printing process and the materials being used.

    Another challenge is the availability and quality of local resources. While Mars has a wealth of raw materials that could be used for 3D printing, it is not yet clear how easily these materials can be processed and transformed into usable materials. There are also concerns about the quality and consistency of the materials, which could affect the strength and durability of the printed structures.

    Despite these challenges, there is a growing body of research and development focused on using 3D printing for Mars colonization. In addition to NASA’s efforts, private companies such as SpaceX and Blue Origin are also exploring the potential of 3D printing for space exploration and settlement.

    One of the key areas of research is the development of new printing materials and techniques that are specifically designed for the Martian environment. For example, researchers at the European Space Agency are exploring the use of a type of biopolymer that can be produced using bacteria and can be used as a building material for 3D printing. This material is lightweight, durable, and can be produced using organic matter that could be found on Mars.

    Another area of research is focused on creating robots and other automated systems that can operate autonomously on Mars, including the ability to perform 3D printing tasks. For example, NASA’s InSight lander has a robotic arm that could potentially be used for 3D printing tasks, while the Mars 2020 mission included a small helicopter drone that could be used to scout potential 3D printing sites.

    Despite the challenges and limitations of 3D printing for Mars colonization, there is no doubt that it has the potential to play a significant role in the future of space exploration and settlement. By allowing us to manufacture objects on-site using locally available materials, 3D printing could greatly reduce the cost and complexity of missions to Mars and other planets. It could also enable us to create structures and infrastructure that are optimized for the unique conditions of extraterrestrial environments, ultimately making it possible to establish permanent human settlements beyond Earth.

    In conclusion, while 3D printing may have once seemed like a science fiction fantasy, it is now a very real and promising technology that could play a critical role in the future of space exploration and colonization. While there are still many challenges and limitations to overcome, the potential benefits of using 3D printing for Mars colonization are too great to ignore. As researchers and engineers continue to push the boundaries of this technology, we may be one step closer to making the dream of a human settlement on Mars a reality.

  • Terran 1, world’s first 3D printed rocket Revolutionizes Aerospace

    Terran 1, world’s first 3D printed rocket Revolutionizes Aerospace

    Relativity Space writing the history by launching the world’s first 3D printed rocket, the Terran 1. This groundbreaking achievement will be a significant milestone in the aerospace industry and represents a revolutionary shift in the way we design and build rockets.

    Traditionally, rocket manufacturing has been a complex and expensive process that involves a large number of parts and specialized equipment. But with 3D printing, the potential to simplify this process and make it more cost-effective is enormous. Relativity Space has leveraged this potential to create a rocket that goes from raw material to flight, integrating artificial intelligence, robotics, and autonomous manufacturing technology.

    The Terran 1 is not only a technological marvel, but it also marks a significant shift in the aerospace industry. With 85% of its mass being 3D printed, the rocket’s primary structures are printed using a proprietary metal aluminum alloy developed in-house by Relativity. This enables the company to radically simplify the aerospace manufacturing supply chain, leading to greater flexibility and customization.

    The rocket is an expendable two-stage launch vehicle powered by liquid natural gas (LNG) and liquid oxygen (LOX) designed for future constellation deployment and resupply. It can launch up to 1,250 kilograms to low Earth orbit (LEO) for dedicated, multi-manifest and rideshare missions. With nine 3D printed Aeon 1 engines on the first stage and one 3D printed Aeon Vacuum (Vac) engine on the second stage, the rocket is 110 feet in height by 7.5 feet in diameter.

    You can watch the live launch stream above.

    The Aeon engines are fueled by liquid natural gas and liquid oxygen, utilizing the gas generator engine cycle. The tanks are autogenously pressurized with gaseous natural gas and gaseous oxygen via heat exchangers integrated into the engines. Relativity Space’s Stargate metal 3D printers enable rapid product iteration, unlocking significant improvements to product development and production.

    The potential of 3D printing in the aerospace industry is vast. The ability to print rocket parts on-demand can revolutionize the way we design and build rockets. With 3D printing, we can reduce the time it takes to produce rocket parts, reduce the cost of manufacturing, and increase the efficiency of the manufacturing process. This could lead to faster and more cost-effective space exploration.

    Relativity Space is building a highly attractive launch service offering by designing and manufacturing reusable rockets that offer high performance and reliability, while costing less to produce and fly. The company’s innovative approach to aerospace manufacturing is driving the inevitable shift toward software-defined manufacturing, which will drive innovation on and off planet Earth.

    Terran 1 – Relativityspace

    The Terran 1 launch is just the beginning of a new era in space exploration. With 3D printing and other advanced manufacturing technologies, we can revolutionize the way we explore space. The potential of additive manufacturing is vast, and we are excited to see what the future holds for this innovative technology.

    3D printing is not only a game-changer for rocket manufacturing but also for spacecraft components, satellites, and other equipment used in space exploration. This could lead to more cost-effective and efficient space missions, making it easier to explore our solar system and beyond.

    At Addithive, we are excited to see Relativity Space and other companies pushing the boundaries of what is possible with additive manufacturing. We believe that 3D printing has the potential to change the world, and we are thrilled to see how it will transform the aerospace industry and beyond.

    The Terran 1 launch is a testament to the potential of additive manufacturing to revolutionize the industry. The rocket is not only a technological marvel but also a symbol of a significant shift in the way we think about space exploration. We are excited to see what the future holds for

  • Unleashing the Power of Additive Manufacturing with Artificial Intelligence: The Game-Changing Revolution You Can’t Afford to Miss!

    Unleashing the Power of Additive Manufacturing with Artificial Intelligence: The Game-Changing Revolution You Can’t Afford to Miss!

    Are you ready to witness the future of manufacturing? Additive manufacturing and artificial intelligence are two rapidly growing technologies that are transforming the way we make things. And when combined, they have the potential to revolutionize manufacturing and beyond.

    Additive manufacturing, also known as 3D printing, is the only manufacturing technology that can be fully digitalized. It involves creating objects layer-by-layer from a digital model, using a range of materials such as plastics, metals, and even living tissue. Meanwhile, artificial intelligence (AI) is enabling machines to learn, adapt, and make decisions like humans.

    The possibilities of combining these two technologies are endless. Anything that seemed impossible before, such as creating complex geometries, personalized medical devices, or self-assembling structures, can now be possible with the power of additive manufacturing and AI.

    In this blog post, we will explore the intersection of additive manufacturing and artificial intelligence and discuss how their combination can lead to revolutionary advancements in manufacturing and beyond. We will delve into the role of AI in additive manufacturing, the potential of AI-powered 3D printing, and the challenges and opportunities of integrating these technologies. Get ready to witness the future of manufacturing and join us on this exciting journey.

    The Role of AI in Additive Manufacturing

    Additive manufacturing involves a complex process of designing, printing, and post-processing. AI can optimize each of these steps to improve efficiency and accuracy. In the design process, AI can analyze data from previous designs to generate new ones that are optimized for strength, weight, and other factors. In the printing process, AI can monitor the printing process in real-time to detect and correct errors. This can reduce waste and improve the quality of the final product. Finally, AI can improve the entire additive manufacturing software toolchain, from design to post-processing, to create a seamless and efficient workflow.

    The benefits of using AI in additive manufacturing are numerous. By optimizing the design and printing process, we can reduce waste, improve quality, and increase speed. This can lead to significant cost savings and improved competitiveness for businesses. Additionally, AI can help us discover new design possibilities and optimize our products for specific use cases.

    The Future of Additive Manufacturing with AI

    The potential of AI-powered 3D printing and additive manufacturing is limitless. In the aerospace industry, for example, AI can be used to optimize the design of components for weight reduction and improve fuel efficiency. In the automotive industry, AI can be used to design and produce custom parts on-demand, reducing the need for large inventories. In healthcare, AI can be used to create personalized medical devices and implants that are optimized for each patient’s unique anatomy.

    The impact of AI and additive manufacturing on the supply chain is also significant. By allowing for on-demand production of parts, businesses can reduce their inventory and supply chain costs. Additionally, AI can optimize the production process to reduce lead times and improve overall efficiency.

    The Challenges of Combining Additive Manufacturing and AI

    Integrating AI and additive manufacturing can be complex, especially in highly regulated industries like healthcare and aerospace. Ensuring compliance with regulations and safety standards is crucial, and R&D and implementation can be expensive and time-consuming. Additionally, there may be limitations to the types of materials that can be used in additive manufacturing with AI, which can limit the range of applications.

    However, there are solutions to these challenges. Collaboration between companies and researchers can help to share knowledge and resources, reducing costs and speeding up the development process. Additionally, advancements in material science are expanding the range of materials that can be used in additive manufacturing, opening up new possibilities for innovation.

    Success Stories and Case Studies

    Real-world examples of companies and researchers using AI and additive manufacturing to innovate and create are abundant. Let’s take a closer look at some of the most exciting success stories and the lessons learned from each.

    • Gas Turbine and Power Generation companies will been using additive manufacturing and AI to optimize the design of gas turbine blades. By simulating different designs and materials, they will be able to create a blade with better aerodynamics and cooling performance. This resulted in higher efficiency and longer lifespan of the turbine.AI and additive manufacturing can lead to better product performance and longevity in the energy sector.
    • Aviation companies will been using additive manufacturing and AI to improve the production process of aircraft parts. By using machine learning algorithms to analyze sensor data from the 3D printers, they will be able to detect and prevent defects in real-time, reducing the amount of waste and improving the quality of the final product.AI and additive manufacturing can lead to better quality control and waste reduction in the aviation industry.
    • 3D printing machine makers will be using AI to improve the printing process and optimize material properties. By analyzing data on the printing process and the behavior of different materials, they will be able to create a software tool that can predict the properties of a printed part before it is printed. This allows for better design optimization and material selection.AI can help optimize the printing process and improve the quality of the final product in additive manufacturing.
    1. Medical Device and Implant companies will be using AI and additive manufacturing to create personalized medical implants. By analyzing data on the patient’s anatomy and bone density, they will able to create a customized implant that fits perfectly and promotes bone growth. This solution is faster, more accurate, and more affordable than traditional implant manufacturing methods. AI and additive manufacturing can lead to personalized medical solutions that are more accessible and affordable to patients.
    1. Automotive companies will been using AI and additive manufacturing to create complex jigs and fixtures for their production line. By using generative design algorithms and 3D printing, they will be able to create customized and lightweight fixtures that are more efficient and cost-effective than traditional methods.AI and additive manufacturing can lead to better tooling solutions that improve efficiency and cost-effectiveness in the manufacturing process.

    These examples demonstrate the diverse range of applications for AI and additive manufacturing. By leveraging data and machine learning, we can create innovative solutions that improve efficiency, sustainability, and cost-effectiveness across a range of industries. The possibilities are endless, and we can’t wait to see what the future holds for this exciting intersection of technologies.

    At Addithive, we believe that the future of manufacturing and innovation lies in the combination of additive manufacturing and artificial intelligence. We encourage businesses and researchers to embrace these technologies and explore the exciting possibilities they offer. The combination of additive manufacturing and AI has the potential to revolutionize manufacturing and beyond. By leveraging data and machine learning, we can optimize the design, printing, and post-processing of parts, improve quality control and waste reduction, create personalized medical solutions, and improve tooling and fixtures for the manufacturing process.

    The benefits of these technologies are clear, and it’s time for businesses and researchers to embrace them fully. By investing in research and development, and implementing AI and additive manufacturing solutions, companies can stay ahead of the curve and gain a competitive advantage.

  • Customization, Efficiency and Sustainability in AM — Updated Guide

    Customization, Efficiency and Sustainability in AM — Updated Guide

    This article has been consolidated into the updated AM guide

    The original article presented customization, efficiency and sustainability as broad advantages of additive manufacturing. These topics now appear in Addithive’s updated pillar guide with more precise engineering context and fewer absolute claims.

    Read the Updated Additive Manufacturing Guide

    What changed

    • Customization is evaluated against design, validation and quality-control cost.
    • Efficiency is compared with tooling, production volume and total post-processing time.
    • Material savings include supports, failed builds, powder refresh and machining stock.
    • Sustainability is assessed at lifecycle and system level rather than assumed from the printing step alone.
    • On-demand production and digital inventory are discussed together with qualification and data-retention constraints.

    The original URL remains live to protect bookmarks and external links, while the updated pillar article is now the authoritative source.

  • Additive Manufacturing for The New Space Age

    Additive Manufacturing for The New Space Age

    The space industry is a great field for new technology development. The challenges such as lightweight and stronger components with the demand for higher trust and lighter rockets that can reach mars propel the demand for more advanced components. Emerging technologies are almost always initiated in space or defense industries because the demand for the better originates in these industries either by war or competition in the industry. Additive Manufacturing is also incepted in the aerospace industry and there are several great examples Large rockets, aircraft engines, satellites are all requires lighter and stronger parts. and the good thing is that the production volume for industrialization of these components way lower than the automotive industry. This makes these platforms a disruptive opportunity.

    Additive manufacturing provides faster cycle time and leaner production of testing components for a space platform program. This both the design cycle of the components and the overall schedule of the development programs. Another advantage of additive manufacturing for space components is the reduction of complexity. Additive manufacturing enables the complexity of the component while reducing the complexity of the overall realization of the component. Combining several sub-parts into a combined assembly that can be built by additive manufacturing. We will go over some of the recent advancements that are developed by different NASA research centers. We will go over Rocket engine component examples that are developed with additive manufacturing technology such as injectors, turbopumps, combustion chamber and more. These advancements are great examples and paves the way to new space age for reaching Mars and beyond.

    Rocket Engine Injectors

    Rocket Engine fuel injectors are simple but one of the most critical of a rocket engine because it defines the theoretical performance of the rocket nozzle. A well-designed injector enables efficient burning of the propellant. In addition to that, injectors help to reduce the thermal loads on the nozzle by cooling the internal nozzle surface with fuel. Injectors can be made by drilling small holes with a designed pattern that fuel and oxidizers travel. The holes break the fuel into small droplets, smaller the droplets burned easily and the efficiency of the combustion increased. The holes are can be drilled in conventional ways but it is costly when compared to additive manufacturing. Rocket engine injector successfully tested at NASA Glenn research center Rocket combustion lab with a benefit of lead time from 1 year to 4 months and 70% less cost. The main cost out opportunity is to reduce the number of parts. The additive injector has 2 parts, while its conventional version has 115 parts. This is a disruptive reduction for both cost, program execution, and simplification of the supply chain.

    NASA/MSFC

    Rocket Engine Turbopumps 

    Rocket Engine Turbopumps produce high-pressure propellant to feed rocket engine combustion chamber. These pumps are designed with turbo-machinery principles and the design of these components is as hard as a jet engine yet a well-designed turbopump can deliver 70–90% efficiency. This particular turbopump makes 90000 revolutions per minute (RPM) to pump propellant. NASA has developed a turbopump in 2015 for liquid hydrogen, which is an ideal propellant for space missions but it is pumped at -240 Celcius. Rocket engine turbopump has 45% fewer parts. Combining several parts into one complex additive part dramatically reduces both costs and the weight of the component. On top of that reducing the number of parts simplifies the supply and realization of the hardware.

    This rocket engine fuel pump has hundreds of parts including a turbine that spins at over 90,000 rpms
    NASA/MSFC

    Gimbal Cone

    There are many methods to change the exhaust direction of the rockets. One of the methods is to use a gimbal system. A gimbaled nozzle tilts the engine nozzle in the proper direction. Below Gimbal cone made of titanium at ORNL, The process used for this component is Electron Beam Melting. When compared to investing casting or other conventional manufacturing methods. The manufacture of titanium components like this gimbal has a great potential to reduce costs as well as lead time and overall weight of the component. Titanium alloys are expensive yet they provide lightweight and strong components. Especially Ti-6Al-4V is a great alloy for rockets, jet engines, and satellites. Of Course, there are challenges like material properties and how are these are changing with the variation of process features. Powder Process microstructure relations are complex and need to be investigated.

    NASA

    Rocket Engine Combustion Chamber 

    Rocket fuel and oxidizer flow in to combustion chamber with the help of turbo pump since the pressure inside the combustion chamber is extremely high. The combustion chamber mixes oxidizer and the fuel. The temperatures inside of the combustion chambers is over 2750 Celcius. This is far more than the melting temperature of copper alloy. In order to protect the chamber from melting during this extreme operation, It is being cooled by the extremely low temperature (-173 Celcius ) gas circulation inside the 200 tiny channels. These channels can only be manufactured by additive technology. It takes more than 10 days to build this rocket component but it is way faster than to manufacture it with conventional ways. Copper is a good heat conducter and this makes it a great match for this application. However, it makes it hard to melt with a laser scan. Overcoming these obstacles is not easy but enables game change rocket engines.

    NASA/MSFC/Emmett Given

    Structural Jacket using EB FFF (Free Form Fabrication)

    Copper combustor liners are good for thermal conductivity but they are not very strong. In order to solve this problem, it is covered with an IN625 (Nickel Alloy) structural jacket. Electron Beam Free Form Fabrication is a directed energy deposition technology. In this technique Electron Beam is used as energy source and it is directed to melt metal wires which are IN625 for this application. It is a very fast process that is developed by Sciaky Inc to deliver 5kg/hour. EB FFF technology derived from Electron Beam welding process which has been used in aerospace industry more than 50 years. One of the challenges of this process it works under vacuum since electron beam can only be generated by vacuum.

    NASA/MSFC/David Olive

    Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) :

    NASA is working on Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) to advance novel design and manufacturing technologies while increase scale, reduce cost, and improve performance of rocket engine components. Key focus areas of the program as below :

    1. Directed Energy Deposition (DED) focusing on blown powder techniques to enable integrated cooled channel wall nozzle.
    2. Multi material additive manufacturing modalities such as bimetallic and multi-metallic deposition techniques focusing on copper and nickel based super alloys.
    3. Engineering and simulation tools to predict and compensate material feed techniques distortion and material properties
    4. Last but not least development of design tools to get full benefit of additive enables design which primarily focuses on integrated cooled combustion chamber and nozzle
    NASA

    Conclusion

    Additive manufacturing is a great tool to reduce weight and cost while improving perfomance. This is exact need for the space technology and next generation rocket engines. Several different additive modalities under investigatin by NASA and these will be utilized on space programs. we observe and extensive use of additive manufacturing technology on space propulsion componentst. There are still problems and issues to advance the technology such as certification of components and development new alloys suitable for additive manufacturing. However these issues are also good opportunities for additive manufacturing industry partners, universities and material producers.

    References :

    Additive Manufacturing of Aerospace Propulsion Components -Dr. Ajay Misra, Dr. Joe Grady and Robert Carter – NASA Glenn Research Center Cleveland, OH – Doc: 20150023067 – https://ntrs.nasa.gov/citations/20150023067

    Lightweight Thrust Chamber Assemblies using Multi- Alloy Additive Manufacturing and Composite Overwrap – Paul R. Gradl , Chris Protz   John Fikes, Allison Clark NASA Marshall Space Flight Center, Huntsville, AL Laura Evans , Sandi Miller6, David Ellis NASA Glenn Research Center, Cleveland, OH Tyler Hudson NASA Langley Research Center, Hampton, VA

  • Additive Manufacturing: An opportunity in a VUCA World

    Additive Manufacturing: An opportunity in a VUCA World

    In the future, we will remember 2020 as a good example or even the start of a Volatile, Uncertain, Complex, and Ambiguous world. VUCA is a term generally used by the military to define war situations. As most of the leadership traits taken from the military, VUCA is also coming from the military. Military trains soldiers for the worst-case scenario where people fight and suffer. Parallel with that best leadership skills and concepts that are leveraged to the business world comes from the military. It has been started to be used in post-cold world era. Globalization and global networks and a more connected world now show us what it really means. 2020 feels like the definition of what is VUCA. If you want to put this term into a dictionary, put it like that:

    VUCA : World in 2020

    World Health Organization is notified on COVID-19 on January 7, and the global economy comes to a risk of recession in 5 months. Travel, Aviation, and Retail industries are the ones that are heavily impacted. Think about the supply chain supporting all of the products and services in these industries. Suppliers in these complex networks are shrinking and going out of business right now.

    Shutting down economies and slowing down global trade disrupted supply chains dramatically. With the reduced demand rate in especially in aviation industry tier 1–2 suppliers started to shrink down their operations. Suppliers are very similar to muscles in the human body. When the economy shrinks like when you stop eating, your muscles shrink first. This is what happens to suppliers right know. They are shrinking and going out of business. As all bodybuilders know well enough, it is tough to rebuild these muscles. A supplier may have a history of 10–20 years, and it can go out of business in a crisis like this in 3–6 months or big suppliers can downsize their operations and shut down their not all but some of the shops. Recovering these muscles is not easy. It is not possible to gain back in 3–6 months what you have built-in 10–20 years.

    OECD data shows that 70% of global trade depends on global supply chains. This is where the global economy drives its power. On the other hand, this network business is so connected and involved that its prone to the butterfly effect. Sometimes weakness may be the result of strength. Viruses like COVID-19 spread much faster in a globally connected network of people.

    Is COVID-19 a Black Swan or an event gets us prepared to the new normal. VUCA is becoming the new normal. This is not only a case for COVID-19. There would be other global changes that have a considerable risk of disrupting the global supply chain by looking at the news from the first month of 2020

    • January 2: Bushfires in Australia
    • January 2:Iranian General Soleimani killed in a US drone strike.
    • January 7: The WHO is notified new coronavirus
    • January 8: Iran launched ballistic missiles to bases in Iraq.
    • January 15: Trump Impeachment Inquiry
    • January 22:Locust outbreak in Kenya
    • January 31: UK Exists EU.

    This was just the first month of 2020 in the 2019 global economy impacted by trade wars. Original equipment manufacturers cannot respond to these changes and quickly adapts to the new normal with a conventional supply chain. There will be disruptions in the global supply chain more than ever because of global, economic, geopolitical, and technological abrupt changes, natural disasters, or competitive strategies.

    Thanks Morpheus

    Additive manufacturing, aka 3D printing, can help to balance the impact of global disruptions like COVID-19. How? Why?

    Additive manufacturing is a new tech that enables manufacturing of parts, even assemblies layer by layer from a computer file by consumable materials. The primary advantage of this technology is flexibility and complexity when compared to conventional methods.

    Oak Ridge National Laboratory

    You can check the above photo from ORNL (Oak Ridge National Laboratory) to understand what are the possibilities with additive manufacturing. The best thing is you do not need tooling for the manufacturing of different components. In conventional manufacturing, there is a set of tooling to enable the manufacturing of the components. For casting, a model and core needed to form casting mold for machining, a holder, and fixtures required for manufacturing. The worst thing is when you need to design the fixtures, tools, and molds before you can manufacture your actual part. It takes time to complete all of the tools and fixtures, and this is why conventional manufacturing is not as agile and flexible as additive manufacturing since there is no need of tools and fixtures for additive manufacturing, it is much easier to build several different parts and products with a single machine without the need of complex tooling.

    A conventional manufacturing shop has engineers technicians to support all of the efforts related to design, manufacture, and maintenance of tooling manufacturing and actual part manufacturing. In additive manufacturing shops, an operator can easily run 4–5 Additive manufacturing machines. An engineer can prepare part files that are needed for these machines. The good thing is when you have a part file that is capable of delivering the requirements of the part/product. The only need is to store this file and consumables. There is no need to store fixtures, tools, or there is no need to hold an inventory. It is possible to manufacturing when there is demand. It is possible to manufacture other parts when there is no demand for the work in hand. An additive manufacturing shop can be a medical device factory, a rocket part factory and automobile part factory at the same time or shift between industries with very little disruptions.

    Think about what we are going through right now. COVID-19 heavily disturbing century-old industries. A manufacturing supplier working in the aviation industry cannot survive this crisis. On the other hand, an additive manufacturing supplier can simply shift to the manufacturing of respirator parts for medical device OEMs instead of Aviation OEMs. It is also possible to continue to manufacture aviation components when the industry recovers from COVID-19 travel restrictions…

    Charles Darwin

    Think about a world that is not possible to plan for the next 6 months. Your production volume may change because of many reasons that are not in your control. An additive manufacturing shop is at least 10 times more flexible than a conventional manufacturing shop. Business with Vision to tackle challenges, Understanding to see the opportunities and Courage to take action and Adapt, it will thrive in a Volatile, Uncertain, Complex, and Ambiguous world.

    Vision, Understanding, Courage, and Adaptability are remedies to the VUCA world, while additive manufacturing is a remedy to the supply chain in a VUCA world.